succesful switch to automatic tailored made pallet ... · succesful switch to automatic tailored...

2
SIMATIC WinCC - Sales Order Report Succesful switch to automatic tailored made pallet manufacturing with Simatic WinCC Cobra Packaging - Blandain - Belgium www.siemens.be/industrie Business Challenge In order to stay competitive and optimize cost price and res- ponse time in the tailor made pallet manufacturing market, Cobra had to switch over from a manual manufacturing to an automatic one. Cobra ordered an automatic pallet production line 3 years ago from a Swedish OEM to control the line. Technical Challenge After 2 years of work, however, the output of the machines seemed too low, there were a lot of emergency stops and general stability problems. By consequence, Cobra asked PS Automation to get the line finally working. Since PS Automation had little or no expe- rience with the used GE Fanuc PLC’s and Mitsubishi panels and there was no source code of the scada installation, they decided together with Cobra to replace everything by standard Siemens products. They faced following challenges : • Reverse-engineering of the non-working existing installa- tion was needed to figure out how the line worked. There was a lack of up to date documentation or plans. • Recipes were stored in proprietary file format on the scada pc and could not be reused for WinCC. Recipe data had to be generated from scratch in the Microsoft SQL Server database using the option WinCC User Archives. Cobra Packaging & Recycling SA manufactures and recycles wooden pallets, packing and boxes, both in standard sizes or tailored made. They are also specialized in repairing damaged pallets according to EPAL regulations and reselling them second hand. Cobra Packaging & Recycling SA has customers in Belgium, The Netherlands and France. It is a family concern working with about twenty employees. • PS Automation had to maintain 2 different WinCC applica- tions to match the existing setup of the different machines. One application had a fairly simple recipe handling because only 1 machine was concerned. The second WinCC applica- tion had a very complex recipe handling with a lot of global scripting needed to control machine and pallet parameters. Recipes had to be conceived in such a way that the 3 machines can be operated separately or together inside the same recipe structure. • Cobra wanted to keep Panel PC’s with Touch screen operation. Standard Recipe handling in WinCC through the User Archive control is easy with a mouse, but not through a touch screen. PS Automation made special pop-up screens with intuitive navigation through big tabs for quick and easy recipe handling by the operators. • Implement an easy-to-use login system for the operators with archiving of all operator actions, especially around recipe handling (modifications & downloads to the plc’s). • Find and solve electro-magnetic network problems due to a wrong network design with too long distances, misplaced cables, wrong connectors, … PACKAGING RECYCLING

Upload: phamcong

Post on 18-Aug-2018

222 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: Succesful switch to automatic tailored made pallet ... · Succesful switch to automatic tailored made ... One application had a fairly simple recipe handling ... scripting needed

SIMATIC WinCC - Sales Order Report

Succesful switch to automatic tailored made pallet manufacturing with Simatic WinCC Cobra Packaging - Blandain - Belgium

www.siemens.be/industrie

Business ChallengeIn order to stay competitive and optimize cost price and res-ponse time in the tailor made pallet manufacturing market, Cobra had to switch over from a manual manufacturing to an automatic one. Cobra ordered an automatic pallet production line 3 years ago from a Swedish OEM to control the line.

Technical ChallengeAfter 2 years of work, however, the output of the machines seemed too low, there were a lot of emergency stops and general stability problems.

By consequence, Cobra asked PS Automation to get the line finally working. Since PS Automation had little or no expe- rience with the used GE Fanuc PLC’s and Mitsubishi panels and there was no source code of the scada installation, they decided together with Cobra to replace everything by standard Siemens products.

They faced following challenges :

• Reverse-engineeringofthenon-workingexistinginstalla-tion was needed to figure out how the line worked. There was a lack of up to date documentation or plans.

• RecipeswerestoredinproprietaryfileformatonthescadapcandcouldnotbereusedforWinCC.Recipedatahadto be generated from scratch in the Microsoft SQL Server database using the option WinCC User Archives.

Cobra Packaging & Recycling SA manufactures and recycles wooden pallets, packing and boxes,

both in standard sizes or tailored made. They are also specialized in repairing damaged pallets

according to EPAL regulations and reselling them second hand.

Cobra Packaging & Recycling SA has customers in Belgium, The Netherlands and France.

It is a family concern working with about twenty employees.

• PSAutomationhadtomaintain2differentWinCCapplica-tions to match the existing setup of the different machines. One application had a fairly simple recipe handling because only 1 machine was concerned. The second WinCC applica-tion had a very complex recipe handling with a lot of global scripting needed to control machine and pallet parameters. Recipeshadtobeconceivedinsuchawaythatthe 3 machines can be operated separately or together inside the same recipe structure.

• CobrawantedtokeepPanelPC’swithTouchscreenoperation. StandardRecipehandlinginWinCCthroughtheUserArchivecontrol is easy with a mouse, but not through a touch screen. PS Automation made special pop-up screens with intuitive navigation through big tabs for quick and easy recipe handling by the operators.

• Implementaneasy-to-useloginsystemfortheoperatorswitharchiving of all operator actions, especially around recipe handling (modifications & downloads to the plc’s).

• Findandsolveelectro-magneticnetworkproblemsdueto a wrong network design with too long distances, misplaced cables, wrong connectors, …

PACKAG INGRECYCL I NG

Page 2: Succesful switch to automatic tailored made pallet ... · Succesful switch to automatic tailored made ... One application had a fairly simple recipe handling ... scripting needed

Sales OrderBranche : wood & recycling Application typical : assembly processEnd-Customer:CobraPackagingandRecyclingSAGeneral Contractor : PS AutomationSystem Integration : PS AutomationLocation : Blandain, Belgium Project Roll-outKick-off : 4Q.2010Engineering phase : 4Q.2010 – Q1 2011Go Live : 02.2011

1st point of contact Arlette Sente, Technology [email protected]

Michel Noerens, Account [email protected]

Patrick Schellynck, CEO PS [email protected]

Siemens n.v

Industry Sector

Industry Automation and Drive Technologies

Marie Curiesquare 30

1070 Brussels

BELGIUM

www.siemens.be/industrie

Sales Order Report

Printed in Belgium

© Siemens nv 2011

Publication date : 1 / 2012

Division : IPS PG1

i/eSoRleadby:TB²D–FA02

Contact

PS AUTOMATION

Chaussée d’Ath 244

7850 Marcq

Tel. : 02/395 52 69

Solution

Cobra wanted an open SCADA system with historical archiving of all production alarms and all production data related to the pallet production: start/stop times of the machines, dimensions of the pallets (Width, Length and Height) and all recipe para-meter settings of the machine.

PS Automation proposed the use of WinCC because of its long-term archiving possibilities in the integrated Microsoft SQL Server database. To archive all production data in the second WinCC application, an Archive PowerPack for 1500 tags was added, because the 512 archive tags available in all basic WinCC licenses was insufficient. Currently, phase 1 of the project is running with production statistics generated with Excel as reporting tool.

Phase 2 will come in a few years. Cobra will invest in an SAP system and feed it with production data coming from WinCC. The goal is to use the WinCC Archive data in the SQL database for internal reporting.

Results at a glance

•Succesfulswitchfrommanualtoautomaticpallet production

•Volumeofpalletproductionincreased3x(to10x for certain pallet types) compared to the manual process.

•TheautomaticmanufacturinghasgivenCobraaclear performance advantage over most of its competitors

•EasytoUseRecipeHandlingSystemfortheoperators.

•AvailabilityofProductionStatisticsthroughWinCC&Excel

•AvailabilityofArchivedproductiondata-Cobraplans

Product Inventory

•PLCControllers: -5xS7-3152DP+FM350-2cards

•IndustrialNetwork:-ProfibusDP(distr.I/O.....) - MPI for SCADA and PLC communication

•HMIsoftware: -2xWinCCV78KRTsystems - WinCC/User Archives option - WinCC Archive PowerPack for 1500 tags

•HMIhardware: -2xSIMATICIPC677C with 19” Touch Screen - 2 x TP177B 6” - 2 x TP177B 4”