ypÊ cleans up production with plantpax system and mes
DESCRIPTION
Brazil's largest hygiene and cleaning products manufacturer, YPÊ, needed improved visibility into their multi-site process to increase productivity and provide real-time data for operators and management. With IASTECH, the company implemented the PlantPAx process automation system, paired with a MES solution, at its Quimica Amparo plant. In addition to gaining decision-making information, the company saw an increase in production on its bottle filling line by 33.2 percent and reduced overall downtime from three hours to one hour. YPÊ has since implemented the solution at five additional locations.TRANSCRIPT
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Cleaning Up Production with PlantPAx and MES Ypê - Brazil
Cláudio Fernando de Jesus
Ypê – Innovation Manager
Rafael Pezzella Chiea
Iastech – Sales Manager
November 17-18, 2014
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Ypê Anapolis / Brazil – A Dream
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Agenda
Conclusions
The Project
The Automation
The New Plant
Ypê & Iastech
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IASTECH
Since 1990
Rockwell Automation Solution Partner
Quality System - ISO 9001:2008
EPM and PMI
More than 1800 projects
Life science, food and beverage, chemical specialist
Rockwell Automation Solution Partner since the beginning of the program ! Rockwell Automation Process Solution Provider !
Rockwell Automation Information Solution !
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Ypê
Since 1950, Ypê is a 100% Brazilian
Company dedicated to make
household products.
Leader company in the laundry soap,
dishwashing liquid detergent and
liquid softener segments.
Other products: bath soap bar, powdered
detergent, laundry detergent, steel wool pads,
multi surface cleaner, scrub sponge.
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Ypê - HPC Product Lines
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Agenda
Conclusions
The Project
The Automation
The New Plant
Ypê & Iastech
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The New Plant – Our Challenges
Quick project turnaround
Totally integrated with ERP system
Levels 0, 1 and 2 – totally integrated
Scalability
High availability
Full remote access
Security
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The New Plant: Main Core with MES and PlantPAx Integration System
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The New Plant: Process Overview
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Agenda
Conclusions
The Project
The Automation
The New Plant
Ypê & Iastech
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Corporate Management
SAP ERP
The New Plant: Integrating Levels
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The New Plant: Integrating Levels
MES (Manufacturing Execution System) SCADA Server
Corporate Management
SAP ERP
View Point
HMI Server
Redundant HMI/Data Server
Data Server
HP Proliant BL460C
05 physical computers 09 virtual
computers
Transaction Historian
FT Directory
Engineering FT View Studio
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Automation Process
Plant Floor
The New Plant: Integrating Levels
MES (Manufacturing Execution System) SCADA Server
Corporate Management
SAP ERP Client 1
EKI-7656C SW001
Deposito
EKI-7656C SW002
Caldeira
EKI-7656C SW003
Processo
EKI-7656C SW004
Det. L1
EKI-7656C SW005
Det. L2
EKI-7656C SW006
Ama. L1
EKI-7656C SW007
Ama. L2
EKI-7656C SW008
Ama. L3
Pos.
Ench.
Etiq.
Enca.
Pale.
Pos.
Ench.
Etiq.
Enca.
Pale.
Ench.
Enca.
Ench.
Enca.
Ench.
Enca.
Client 2
Client 3
Ethernet TCP/IP
Flow meter
Ethernet/IP
Pressure
4...20mA / Hart Inverter
DeviceNet
Weight System
DeviceNet
Temperature
4...20mA / Hart
Conductivity
4…20mA / Hart
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Automation Process
Plant Floor
The New Plant: All Integrated Levels
MES (Manufacturing Execution System) SCADA Server
Corporate Management
SAP ERP
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The New Plant: Preparation Automation Hardware Overview
Process Control
Mixer 01 Mixer 02 Mixer 03
Dosing Unit
Mixer 01 Mixer 02 Mixer 03
Dosing Unit
Liquid Detergent Liquid Softner
Utilities Pharmacy Silo
ControlNet_1
Client 01 Client 02
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The project: Preparation Automation Hardware Architecture
ControlLogix 5562 CPU
(4 MB)
352
336
48
16 20
ControlNet 1 I/O’s
DI
DO
AI
AI (Hart)
AO
RmCn Torre 2
RmCn Utilidades
RmCn R1 Deterg.
RmCn R2 Deterg.
RmCn A1 Amac.
RmCn A2 Amac.
RmCn L3 Amac.
RmCn R3 Deterg.
RmCn Torre 1
RmCn Dosador D.
RmCn Dosador A.
RmCn Farmácia
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The project: Preparation Automation Hardware Architecture
DeviceNet 2:
08 x POWERFLEX 753
Preparation CCM
DeviceNet 1:
14 x POWERFLEX 753
Utilities CCM
DeviceNet 3:
10 x Alfa 2710D - 2 Channels
Weight System
ControlLogix 5562 CPU
(4 MB)
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The New Plant: Storage Automation Hardware Overview
Storage Control
Unit 01 Unit 02
Desmineralized Water
Remote 02
Remote 01
Storage Remotes
Remote 03
Manifold Remotes
Line 01 Line 02
Line 01 Line 02
Liquid Detergent
Line 03
Liquid Softener
Main
ControlNet_2 ControlNet_1
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The project: Storage Automation Hardware Architecture
RmCn Depósito1
RmCn Descarreg.
RmCn L1 Deterg.
RmCn L2 Deterg.
RmCn L1 Amac.
RmCn L2 Amac.
RmCn L3 Amac.
RmCn Manifold
RmCn Desmi1
RmCn Desmi2
RmCn Depósito2
RmCn Depósito3
128
96
0
80
0
ControlNet 2 I/O’s
DIDOAIAI (Hart)AO
232
200
4 64
0
ControlNet 1 I/O’s
DIDOAIAI (Hart)AO
ControlLogix 5562 CPU
(4 MB)
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The project: Storage Automation Hardware Architecture
DeviceNet 2: 13 x POWERFLEX 753 End Product Storage CCM
DeviceNet 1: 25 x POWERFLEX 753 Raw Material CCM
ControlLogix 5562 CPU
(4 MB)
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The New Plant: Filler Lines Automation Hardware Overview
Line 01
Liquid Detergent
Line 02
Line 01
Liquid Softener
Line 02
Line 03
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The project: Filler Lines Automation Hardware Architecture
CompactLogix L35E CPU (1,5 MB)
Filler Line CCM
DeviceNet 1: 12 x POWERFLEX 40
64 32
8 8
Local I/O’s
DI
DO
AI
AI (Hart)
AO
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The project: Filler Lines Automation Hardware Architecture
For Five Filler Lines
320 160
40 40
Local I/O’s
DI
DO
AI
AI (Hart)
AO
60 x POWERFLEX 40
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The project: Totalized Hardware Numbers
CONTROLLERS, NETWORKS AND EQUIPMENTS.
1032
792
92 160 60 Totalized I/O’s
DI
DO
AI
AI (Hart)
AO
2 x ControlLogix
5562 CPU (4 MB)
5 x CompactLogix
L35E CPU (1,5 MB)
DeviceNet
10 x DeviceNet
ControlNet
3 x ControlNet
60 x POWERFLEX 40
60 x POWERFLEX 753
10 x Alfa 2710D
2 Channels Weight
System
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The project: Software SCADA / MES
PROCESS AUTOMATION SYSTEM SERVER - PASS
1 x FactoryTalk View Site Edition Server 100 Display with RSLinx; 9701-VWSS100LENE
11 x FactoryTalk View Site Edition Client 9701-VWSCWAENE
1 x FactoryTalk VantagePoint 9521-VPCL03ENE
1 x FactoryTalk Historian Site Edition 9518-HSERA1K
1 x FactoryTalk ViewPoint 9522VWP03RENE
MSSQL
1 x MSSQL2008 Standard
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PlantPAx – Liquid Detergent Preparation Screen Shots
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PlantPAx – Liquid Softener Preparation Screen Shots
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PlantPAx – Storage Screen Shots
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PlantPAx – Air, Water and Pharmacy Utilities Screen Shots
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PlantPAx – Desmineralized Water Screen Shots
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PlantPAx – Filler Lines Screen Shots
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PlantPAx – FactoryTalk Historian Screen Shots
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PlantPAx – MES Screen Shots
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PlantPAx – MES Screen Shots
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PlantPAx – MES Screen Shots
Production Reports
Production Times
Dosage Deviations
Level of Storage Tanks Raw Material and End Products
Inventory Control
WEB SCADA Application
Audit Trail
SAP System Orders Control
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PlantPAx – MES Screen Shots
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PlantPAx – FT ViewPoint Screen Shots
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PlantPAx – SAP / MES / SCADA Overview
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PlantPAx – SAP / MES / SCADA Integration Screen Shots
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PlantPAx – SAP / MES / SCADA Integration Screen Shots
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PlantPAx – SAP / MES / SCADA Integration Messages and Interfaces
Get sample to send to the Quality Control
Warning! There are corrective measures for this batch.
Waiting end of corrective measures for this batch.
Waiting end of analyses of corrective measures for
this batch.
Interface to operate the corrective measures.
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PlantPAx – SAP / MES / SCADA Integration Messages and Interfaces
Batch Successfully finalized.
Do You want report consumptions for SAP System?
Batch finalized with corrections.
Please call your supervisor to report consumptions
for SAP System?
Batch finalized with corrections.
Do You want report consumptions for SAP System?
Batch approved!
Do You want to move the balance?
Waiting status available for use from SAP System to
initiate transfer.
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PlantPAx – SAP / MES / SCADA Integration Messages and Interfaces
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PlantPAx – SAP / MES / SCADA Integration Messages and Interfaces
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PlantPAx – SAP / MES / SCADA Integration Messages and Interfaces
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Agenda
Conclusions
The Project
The Automation
The New Plant
Ypê & Iastech
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Main Project Phases
Process
Process Definition;
Process Description;
Batch recipes description;
Operation Analyses;
Functional Specification;
Operation Design;
Automation
Hardware Design Specification;
Control Architecture design;
Control Software Programming;
Factory Acceptance Tests with process
simulation – FAT.
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Main Project Phases
Plant Construction (12 months in total);
Electrical panels and hardware (3 months);
Specifications, Software and FAT (3 months);
I/O test (15 days);
Batch and recipes test (20 days);
Commissioning and Start-up (30 days);
Site Acceptance Tests – SAT;
Operator Training - Operation Tests;
Assisted Operation.
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Agenda
Conclusions
The Project
The Automation
The New Plant
Ypê & Iastech
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Achievements
With this project:
High system reliability;
Full integration with SAP System (MM, QM, PP);
Control over production orders;
Operator can control the whole process;
Historical data and Audit Trail;
Process reports and real time calculations;
High efficiency process;
Easy automation diagnosis and maintenance.
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Teamwork
IASTECH Gestão e Automação Industrial
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Ypê Anapolis / Brazil – From Dream to Real Plant
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Questions
Cláudio Fernando de Jesus
Ypê – Innovation Manager
Rafael Pezzella Chiea
Iastech – Sales Manager
November 17-18, 2014