industry: chemicals brisa bridgestone sabancı lastik · pdf file2001 with bimsa as...
TRANSCRIPT
“Thanks to Invensys Wonderware Solutions, we are able to monitor performance better and we are assured that the right products are being manufactured. This enables us to conduct accurate analyses and make the right decisions.’’
Mustafa TacettinFactory Automation Systems Mgr.Brisa Bridgestone Sabanci Lastik
Brisa Bridgestone Maximizes Operational Efficiency with Invensys Wonderware Software Solutions
Goals• Create a flexible and user friendly solution
that will measure the performance of the machines used in manufacturing and ensure the effectiveness and efficiency of the production processes
Challenges• Make sure that the solution will
allow that operators perform the work in the right time and order
Solutions and Products• Wonderware® InTouch® HMI• Wonderware InTrack Software
Manufacturing Execution Module (MEM)
Results• With the Wonderware solution all the
materials used in manufacturing are correct.• The new MES allows for the measurement of
performance. This allows plant management to accurately measure and analyze all production information so that they could make the best manufacturing decisions.
INDUSTRY: CHEMICalS
Brisa Bridgestone Sabancı Lastik San. ve Tic. A.S.www.brisa.com.tr/English
Istanbul, Turkey — Brisa was originally established by the Sabancı Group , a leading industrial conglomerate in Turkey, under a licence agreement signed with the US based BF Goodrich Company in 1974. Production started in 1977 and the sales were extended to 60 provinces in Turkey through 186 organized dealers. The Company produces tires under the lassa brand, expanding its product range from tires for passenger cars, trucks and buses to farm and off-road vehicles.
In response to increased demands for tires globally, a joint venture agreement was signed between the Bridgestone Corporation of Japan, one the world’s largest manufacturers of tires and the Sabancı Group, on November 1st, 1988, each party holding an equal share in the new Company. as a result of this agreement, the Company name was changed to BRISa Bridgestone Sabanci Tire Manufacturing and Trading Inc. Ground breaking for the new plant was completed in July of 1989 and on November 1990, mass production of tires started at the new plant.
For Brisa , the new plant also symbolized a new concept of manufacturing centered on better management, production and increased quality.
Today, Brisa is the number one tire manufacturer in Turkey and the sixth biggest tire producer in Europe. Brisa is recognized internationally because of its achievements in Total Quality Management (TQM). It fully targets total customer satisfaction and continues to build its future on business excellence.
Wonderware Solutions Enables Correct Decision MakingIn a Brisa project called ‘Shopfloor,’ initiated in 2001 with Bimsa as consultants, Wonderware products were used right from the start. InTouch HMI and InTrack MEM of Wonderware were used to control the production operations, set machine parameters and to save the data obtained from the machine as products are being manufactured.
Information is gathered from the Wonderware solution from machines of different manufacturers. Quite a feat considering the different communication standards and interfacing that needs to be done. What Wonderware provides is a standard user interface to interact with these multiple devices. This helps in product quality as the right product is manufactured, operator and machine performances are measured better.
One of the prime objectives of this project is to create an MES that would combine multiple machines which are logically very different from each other under a single system. It was in 2006 when Brisa was able to include the first machine in the Shopfloor system and the project was finally completed in 2008.
How Wonderware ChangedBrisa’s Work Processes
Brisa Factory automation Systems Manager, Mustafa Tacettin explains why they prefer Invensys Wonderware products: “With this project, we wanted to capture the performance of the machines used in manufacturing and make sure that all events in the production are tracked. again with the project, we wanted to be able to stop the machines, when something wrong occurs during production that could affect the quality of the product. This solution is going to be used for a long time and had to be designed properly. For such a long term solution, we decided the best products to use would be the Wonderware InTouch HMI and InTrack MEM.
“Here is a perfect example on how this project changed our work processes for the better: prior to this new solution, to produce a product, engineer would enter production parameters for the machines using a stand alone system. The operator would then manually enter machine output in a separate instrument. If the operator forgot or if he or she entered a wrong value, there would be major errors in the production.
“With this new Wonderware solution, parameter are entered by the respective engineer on the computer in the office, and the instructions are fed immediately and automatically to production machines. Thanks to Wonderware, production can be controlled efficiently and operator performance is much better. Thus, Brisa can conduct accurate analyses and make the right decisions.”
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