material tracking and mass balancing in chocolate manufacturing stefan la grange (amr automations)...
TRANSCRIPT
![Page 1: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/1.jpg)
The Magical World of Chocolate Manufacture
![Page 2: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/2.jpg)
Material tracking and mass balancing in Chocolate Manufacturing
Stefan la Grange (AMR Automations)Fiona Byrns (for Orley Foods)
![Page 3: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/3.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
![Page 4: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/4.jpg)
Mixing
•Cocoa Butter or Equivalent•Sugar or SweetenersGrin
ding
•Cocoa Mass or Powder•Emulsifiers•Powdered Milk
Liquefaction
Chocolate manufacture
Pressure and Temperature measurement
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Project Scope
Orley Foods Manufacturing
Raw Material Receiving
Chocolate Manufacture
Fat Supply
Fat Melters
Storage
Tanks
Heat Exchangers
Mixing
Conches/
Grinding
Storage &
forming
Sugar Manufacture Finished Goods
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Background to the Project
► Seamless and transparent integration throughout the Company manufacturing systems and business system
► Manufacturing system designed for expandability, ease of integration and contextuality.
► Information that is important, relevant and contextual to be published to a portal for easy access
► Ability to trend and trace process issues and speed up trouble shooting.
![Page 7: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/7.jpg)
Project Goals
► Traceability of fat usage and additions against works orders
► Monitoring / logging of process parameters► ERP integration to Syspro► Overall system upgraded to latest technologies
▪ Network▪ Windows / SQL Server environment▪ SCADA system▪ PLC system
► Ingredient management of recipes► Introduction of expandable reporting
infrastructure
![Page 8: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/8.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
![Page 9: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/9.jpg)
Tender process
► Requirements of integrator and solution▪ Cape Town presence▪ Instrumentation, PLC, SCADA and database
development experience▪ Previous experience in food and beverage
industry► Several solutions investigated
▪ Siemens▪ Rockwell▪ Citect
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Why Wonderware
► Proven functionality in the Food and Beverage industries
► Proven integration into business systems (SQL database)
► Well supported, widely used nationally and internationally
► Several solution providers / system integrators▪ Development into the future▪ Increased availability of resources (call-outs)
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Project Design
► Functional specification prepared
► Detailed design process▪ Network topology
▪ PC/Server infrastructure
▪ PLC infrastructure
▪ Data flow
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Project Description
► Develop ArchestrA model▪ S95 standard▪ Model includes future upgrades
► Use model to define data capturing points for EOM
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Topology
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EOM
![Page 17: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/17.jpg)
Project Design
► Design Intouch SCADA▪ Dual display
► AMR’s first project with ArchestrA 3.0 and Intouch 10.0
► Converted AMR’s standard valve/motor SmartSymbols to ArchestrA graphics
![Page 18: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/18.jpg)
Project Design
![Page 19: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/19.jpg)
Project Description
![Page 20: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/20.jpg)
Project Description
![Page 21: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/21.jpg)
ERP Integration / WO Management
► ERP integration to Syspro via holding database▪ WO’s pushed down from Syspro indicating
• Raw material, tank and equipment allocation/scheduling
► Operators start and complete WO’s SCADA
Syspro serverWonderware
Historian
Intouch SCADA
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ERP Integration / WO Management
► Example of WO Management at SCADA level
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ERP Integration / WO Management
![Page 24: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/24.jpg)
![Page 25: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/25.jpg)
![Page 26: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/26.jpg)
Project Description
![Page 27: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/27.jpg)
Project Description
![Page 28: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/28.jpg)
WO – Modify execution time
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WO – Re-allocate
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WO – Remove from plan
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PLC
► Allen-Bradley Compact Logix
► Beckhoff Ethernet/IP remote I/O units
► Program designed with complete process control management in mind (for future phases)▪ Manufacturing instructions
▪ Process parameters (Mixing times, pressure and temperature checks and operator prompts)
▪ Fat transfer route allocation
► Current program only handles fat transfer route allocation
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Reporting
► Wonderware Information Server
► MS-SQL Reporting services
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Reporting
![Page 34: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/34.jpg)
Reporting
![Page 35: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/35.jpg)
Reporting
![Page 36: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/36.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
![Page 37: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/37.jpg)
Benefits / Goals Achieved
► Batch size consistency▪ No need for extensive additions to correct
recipe failures► Raw material allocations tracked
▪ What fat goes where► Better process control tracking
▪ Alarming at SCADA level▪ Trouble-shooting (temperatures, pressure,
grinding times)▪ Operators
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Benefits / Goals Achieved
► Significant savings in fat usage► Batch processing times where standardized
▪ Less usage of resources i.e. power► Minimised batch/formulation corrections
▪ Savings in additional raw materials to batches.
![Page 39: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/39.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
![Page 40: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/40.jpg)
Lessons Learned (PLC)
► User defined data structure always good (duplication of devices similar control)
► I/O server integration with tagnames instead of address reference
► Ethernet/IP needs managed switches to handle IGMP Snooping (Internet Group Management Protocol)
![Page 41: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/41.jpg)
Lessons Learned (Wonderware)
► Domain Security▪ Tighter control with existing business system and
network policies▪ Client responsible for user manager/rights (IT
department)
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Lessons Learned
► Understanding scope and planning vital▪ Previous projects failures overcome▪ Plant downtime was managed
► Plant process visibility greatly improved▪ Updated P&ID▪ Operations / process flow
► Increased speed of data availability
![Page 43: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/43.jpg)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
![Page 44: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/44.jpg)
Project summary / conclusions
► Phase I successfully completed by AMR using Wonderware technology▪ Increased process control and shop floor visibility
► Phase II will further utilize the solution into other areas of the plant
► Future phases will allow for data to be written back to Syspro▪ Automatically closing works orders
![Page 45: Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)](https://reader030.vdocument.in/reader030/viewer/2022032600/56649db55503460f94aa722a/html5/thumbnails/45.jpg)
Thank you