cs08 country maid-interstates control systems

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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Country Maid Gains Production Intelligence to Meet Growing Demand

Raymond Berning

Lead Control Systems Analyst – Interstates Control Systems, Inc.

Marc Banwart

Systems Integrator – Country Maid

November 2014


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Agenda

Question/Answer

Overview of Project Results

Overview of Project

Introduction of Country Maid


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Country Maid

Helping Others Help Themselves

Located in West Bend, IA.

Started in 1991

Fundraiser Driven

Fundraising program focus: A proven product

A simple program

A great experience

100% ESOP

65 Employees http://www.butterbraid.com/

http://www.butterbraid.com/

http://www.butterbraid.com/


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Agenda

Question/Answer


Overview of Project



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Case Study - Country Maid

Where things started…

Fully manual system

Hand batching Hand scaling Start/stop push buttons Manual data entry

Paper records

Overview of old process


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Multiple additions to the process

New mixer


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Second line

Automated flour loop


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Automated ingredient feeders

Packaging robot


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Application – Technical Components

Virtual infrastructure

FactoryTalk® View Site Edition (SE) server FactoryTalk® Batch server – campaign manager FactoryTalk® Historian server FactoryTalk® VantagePoint® server Four FactoryTalk View SE clients

One mobile app – iPad®

PlantPAx® Library

V2.00.10


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Architecture Layout


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The Why’s

Why do the project?

Wanted batch data recording Quality control data

Tighter control on the process Recipe control

Operator interaction history Traceability


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The Why’s

Why choose Rockwell Automation, FactoryTalk Batch, PlantPAx?

Wanted to invest on a platform that provides scalability Allow easy growth in the future as more lines are incorporated

Wanted to drive away from a proprietary solution Wanted built-in maintenance/engineering functionality to help with

trouble shooting equipment Wanted a well documented library

PlantPAx Library v2.00.10


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Agenda

Question/Answer


Overview of Project



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Results

Country Maid was able to reduce labor hours per units produced

significantly

The increased throughput allowed Country Maid to utilize existing labor more efficiently

Developed better control methods using historical data and system

flexibility to increase throughput of the mixer

Operators were given the ability to recreate events to discover issues in the process, procedures or mechanical equipment

The quality control data became substantially more valuable


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Results

25% increase in production per Line

Savings of batch labor costs by $90,000 / year

Reduction of mix times by 23%

The reduction of mix times allowed Country Maid to purchase a smaller mixer, which in turn saved $120,000 in equipment cost, as well as significant structure modifications

Increased line speeds by 14%


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Media- Country Maid

How its Made Friday November 21st 8pm. CST Science Channel USA


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Agenda

Question/Answer


Overview of Project



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Questions

Raymond Berning

Lead Control Systems Analyst – Interstates Control Systems, Inc.

Marc Banwart

Systems Integrator – Country Maid

November 2014

cs08 country maid-interstates control systems

Technology