AP18 - Southwest Baking Company: Applying FactoryTalk Batch For Flexibility and Modularity

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Name - Arial Narrow 16pts

Title - Arial Narrow 16pts

Date - Arial Narrow 16pts

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Southwest Baking Improves Flexibility, Reduces Costs with FactoryTalk Batch

Robert Wroblewski

Plant Engineer

Randy Otto

Systems Integrator

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED

Agenda

Control Software Upgrade

Batch System Upgrade

Solution and Results

Challenges

Southwest Baking, History


Southwest Baking LLC.

3

High Speed Production Facility

Operating at 85-90% Capacity with a Skeleton Crew

Have no room for downtime or inefficiency in our process

OEM Batching system in place

Did it work?

It ran, reported

Reliable? Accessible? Efficient?

History:


Southwest Baking LLC.

4

Limited Flexibility and Accessibility

Solely Based on Ladder Logic

Tied to ridged programming constraints

Had no access to system to repair

Data Collection and reporting

Industry is changing,

We needed accurate, usable reports – now, not tomorrow, not the next day!

Challenges with OEM

We Needed a workable, reliable, stable, expandable System

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 5

Southwest Baking LLC

Needed to replace our limited system

Looked at other Solutions

OEM Software, Other generic solutions

Contacted our Rockwell Automation

FactoryTalk® Batch Demonstration of the PlantPAx® concept

Offered the Flexibility, Data Collection, Accessibility

Learned about the S88 Programming Standard

Added the Ability to be more adaptable to the customer, through its Modularity

Worked with ECS Solutions

FactoryTalk Batch was the Solution

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 6

Southwest Baking LLC

Reduced Draw time: possible tor run at Maximum Capacity

Changes Recipes, ingredient orders without major program changes

Modularity – allows us to keep up with Customer needs quickly and reduced cost

Delivery accuracy – making Nutritional panel possible for each batch we run

Data collection, Reporting – reliable, accurate, we have years of usable data

ROI – Financial return,

Best ROI is Doing what is right for the customer, associates and the future

Results


Agenda

Control Software Upgrade

Batch System Upgrade

Solution and Results

Challenges

Southwest Baking, History


Control and Information Solutions for Industry

8

Founded in

1977

Evansville, Indiana

15,000 SF

building, with

panel shop

specializing in:

Batch and Batch/Continuous Process Control Solutions


From ECS’s Perspective

ECS was contacted to investigate the need to replace the batch

system

Objective: Existing batch system was obsolete and operating on a

failing computer

6/2/20

15

9


Batch System Upgrade: DEFINE

10

LISTEN

EVALUATE

VALUE-FOCUS

JUSTIFY

Obsolete batch computer and software

Can existing control software be reused

Campaign Mgmt, Material Mgmt, Reporting

Single instance of a batch computer failure costs

more than this project


ControlLogix®

Pro

ced

ura

l

Co

ntr

ol

Recipe

Management

System

Operator

Control

Batch System Upgrade: DELIVER

11

FactoryTalk® View SE

VALUE-FOCUS

• Campaign Management

• Material Management

• Reporting

Batch

Management

System

INTERFACE


Batch System Upgrade: RESULTS

20% cycle time savings

Reduction in downtime (average of 4 hours/event -> 1 hour/event)

Code was clumsy and difficult…

Equipment was not separated from the procedure

PLC program was not in small manageable blocks

making modifications to batch procedures required making changes to PLC code

HMI was not integrated very well with batch

6/2/20

15

12


Control Software Upgrade: DEFINE

13

LISTEN

EVALUATE

VALUE-FOCUS

JUSTIFY

Limited flexibility

Feasible based on previous experience, results

Enable the operator, accuracy/consistency

Flexibility would pay for itself in 1 year


ControlLogix

Pro

ced

ura

l

Co

ntr

ol

Operator

Control

Control Software Upgrade: DELIVER

14

Batch

Management

System

NEW CONTROLLER

PROGRAM

VALUE-FOCUS

• System Flexibility / Agility

• Enabling the Operator

• Accuracy

FactoryTalk View SE

NEW HMI

15


Control Software Upgrade: RESULTS

22% reduction in cycle time

Accurate delivery of ingredients

Reduction in downtime (average of 1 hour/event -> 3 minutes/event)

6/2/20

15

16


CONCLUSION

Applying the ISA-88 Standard “the right way” increases value

Changing software only can achieve results

Look for high value savings, they exist in all process systems,

sometimes with little cost

6/2/20

15

17


Please take a couple minutes to complete a quick session survey to tell us how we’re doing. On the mobile app:

1. Locate session using Schedule or Agenda Builder.

2. Click on the thumbs up icon on the lower right

corner of the session detail

3. Complete survey

4. Click the Submit Form button

Thank you!!

3

1

2

4

We care what you think!

www.rsteched.com

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. RSTechED 2014 @RSTechED #RSTechED

PUBLIC INFORMATION

Questions?

Technology

AP18 - Southwest Baking Company: Applying FactoryTalk Batch For Flexibility and Modularity