When GIMA
Spa, a pioneering company among system manufacturers in the “Packaging Valley”
region of Bologna in Italy, was asked by WRIGLEY, a world leader in
confectionery manufacture, to provide a standardised supervisory system that
would provide OEE data across all its different client product lines, the
company turned to Progea’s Movicon 11 SCADA for a
solution.
The
challenge required designing an auto-configurable system that was capable of
connecting to machines independently of their type and configuration. This meant
that a modular and flexible software platform was required: one that was capable
of managing an all-in-one standard project, and designed to connect to any
product line machine, irrespective of type or number employed, to obtain the
necessary information on production status and provide analysis on productivity
efficiency.
The
Movicon Scada/HMI platform was chosen as the ideal solution for achieving the
stated system objectives, and of reaching the pre-planned production goals
quickly and safely. Although working on a limited budget, GIMA Spa not only
satisfied their confectionery client’s needs using the Movicon platform, but is
now able to provide the standardised ‘added value’ system that the company
engineered to other clients, including those from completely different market
sectors.
“Zero”
Maintenance Supervision
The production line supervision and analysis system based on Movicon has been designed to interface to a number of machine variables, not exceeding ten in number. The machines can be fitted either with a Siemens or Elau control units, both offering immediate project auto-configuring to machine production requirements, without requiring additional input or modification.
The production line supervision and analysis system based on Movicon has been designed to interface to a number of machine variables, not exceeding ten in number. The machines can be fitted either with a Siemens or Elau control units, both offering immediate project auto-configuring to machine production requirements, without requiring additional input or modification.
OEE and
Downtime Statistical Analysis
The system’s task is to connect to the machines and highlight working statuses; display alarms - defined as ‘blockers’, and store all significant data, construed as alarms and production data.
The system’s task is to connect to the machines and highlight working statuses; display alarms - defined as ‘blockers’, and store all significant data, construed as alarms and production data.
This data
is collected and displayed on the appropriate graphical summary screen pages,
providing a clear overall picture of ongoing production situations in real-time,
to enable managers to control the production process far more
efficiently.
The main
Movicon supervisor page informs users about production status, by representing
the production line machine images graphically and by supplying data on: Batch
number IDs; Product Settings; Product type; Batch name assigned by customer; Set
quantity of units; Quantity of units produced; Unit percentage Produced;
Production line working time of current batch; Production line speed; and the
Time allotted for operatives working the current shift.
A screen
page is provided for each machine in the system and these pages, when ‘clicked’,
show all details and information relating to that production station.
Complementing these pages, production line graphics appear automatically in
conjunction with the number of machines enabled and operating in the production
line at any particular time. A proprietary designed page has also been provided
to manage production line batches and work shifts: the machines having been
programmed to begin working only when assigned to a production batch. This is
complemented by a production batch data import/export function to MsExcel
formats facility.
The main
objective is to record all data in database archives (Ms SQL Server 2000 was
chosen from the various formats provided by Movicon) for performing statistical
analysis that allow the end user, and builder, to obtain historical information
in order to evaluate critical areas and intervene appropriately to improve
production, reduce machine downtimes and increase the overall productivity
index.
The
supervisor performs statistical analysis on recorded data by
managing:
• Alarm
statistics (frequencies, durations) displayable both in table and graph
format.
• Statistical graphics of on line productivity (includes a pie chart based on 100% time=shift; a general product line pie chart; and one for each machine, together with machine MTBF, MTTR, MDT indices)
• Tables for displaying production counters for selected time range.
• Tables for displaying alarm list history
• Statistical graphics of on line productivity (includes a pie chart based on 100% time=shift; a general product line pie chart; and one for each machine, together with machine MTBF, MTTR, MDT indices)
• Tables for displaying production counters for selected time range.
• Tables for displaying alarm list history
This data
is managed in reports, where data on production, alarms and work settings can be
displayed in table or graphical formats (Pie charts or histograms). This data is
selectable using filters to retrieve data by Time period, Batch number, or
Production batch.
The data
displayed in tables can be exported in Excel files using the command provided.
In the section dedicated to reporting, the system calculates and displays
performance efficiency indices according to the OEE standard. At the end of each
shift, the system will automatically create an Excel file containing production
line information and send it to the predefined recipients by email (this
function can be enabled/disabled as desired). The flexibility of the system
means that the “Target” OEE value can be customised, without modifying the
project, to get coefficient calculations for each specific production
requirement. All information or settings are subject to security management, as
are user ‘Log-ons’.
Thanks to
the statistical information provided by the system, the end user and builder are
able to obtain all the information required to analyse production effectively.
This process involves comparing real data with theoretical data to obtain
crucial information to remove production bottlenecks and improve overall
productivity. In addition, the machine downtime analysis function allows fast
intervention, identification and analysis of the most frequent downtime causes,
enabling the end user to optimise preventative maintenance to avoid the costs of
lost production.
Remote
Analysis via the Web
All statistical information gathered from the Movicon OEE system is available to authorised remote users: production line maintenance personnel, maintenance technicians or GIMA design engineers. Thanks to the Movicon Web Client, the supervisory system is accessible with any browser connecting remotely (internet, intranet). Web client users, assigned with authorised access passwords, can view any information they require in real-time, or the results of statistical analysis, by accessing from any point with a normal browser or mobile device (i.e. Smartphone).
All statistical information gathered from the Movicon OEE system is available to authorised remote users: production line maintenance personnel, maintenance technicians or GIMA design engineers. Thanks to the Movicon Web Client, the supervisory system is accessible with any browser connecting remotely (internet, intranet). Web client users, assigned with authorised access passwords, can view any information they require in real-time, or the results of statistical analysis, by accessing from any point with a normal browser or mobile device (i.e. Smartphone).
The
Movicon solution provided by GIMA not only meets all client requirements, but
offers the added benefit of an unrestricted licence that allows users to
purchase only what they need. This optimises the costs of the Movicon licence in
relation to the size and number of plant production lines
controlled.
“This
latest flagship project for Movicon highlights, once again, the processing power
of the system at a price that enables projects to be brought-in consistently
under budget,” said Paul Hurst MD of P4A, the Movicon distributor in the UK.
“Historically, SCADA systems have been more expensive in the UK than anywhere
else; and with restricted licences, development costs and yearly system
integrator fees, costs are getting out of hand. We are changing this situation
with Movicon 11,” by offering all the functionality, scaleability, connectivity
– and more – of existing SCADA systems, but at a price 30% to 50%
less”
Photo
Captions:
An example of a screen page provided for each machine in the system
and these pages, when ‘clicked’, show all details and information relating to
that production station.
One of the screens used in the Gima Spa production machine line supervision.
Alarm statistics (frequencies, durations) displayable both in table and graph format.
Thanks to the Movicon Web Client, the supervisory
system is accessible with any browser connecting remotely.
The challenge required designing an auto-configurable system that was capable of connecting to machines independently of their type and configuration.
About P4A
Products4Automation (P4A) is a specialist supplier of new and
innovative software and hardware solutions to the UK market. Products ranges
available from P4A include the latest touch-screen HMI's and flat panel PCs,
SCADA software and plug-ins, a wide range of SCADA enabled hardware, Alarm
plug-in software for large automation systems, and a full range of Production
Intelligence software solutions.
