Integrator

An existing Ignition user had need to replace their third-party SPC software. The existing SPC solution was disconnected from the job and key information. The customer requested a pilot of the Sepasoft SPC to extend the capabilities of their Ignition implementation.

ATS jump started the customer’s capability with SPC via a rapid pilot on a few key machines. Proving the value of the module with accurate recording, tracking of data, and integration with test equipment, the customer continued a roll-out to the entire facility. As new lines go in, SPC will be extended to them. In the customer’s words: “It was well received on the plant floor...and by management. It’s now mission critical.”

The customer is a leading company in the design and manufacturing of packaging for commercial products with multiple sites across the US.
They wanted to start collecting OEE and downtime data from all sites and have it available in real time, both locally and from a central location.
Since all sites are of two different types, the customer wanted ATS to develop a pilot solution per site type that could easily extend to the remaining sites.
ATS completed a pilot project where two template projects were developed - one per site type - with all resources such as OEE monitoring, downtime management, dashboards, operator screen, charts, reports, and system configuration. With the project inheritance properties available in Ignition 8, ATS created a child project on each site, which inherits all resources from the template project while allowing the development of custom screens, reports, etc.
ATS also developed an enterprise project where authorized users have an overview of all sites, with drill down options to each line on any site.
In addition to the Ignition and Sepasoft work, ATS also helped the customer with the integration of legacy controllers and the installation of sensors for the MES counters.

The customer faced a common issue: various papers/forms in the plants. The SOP on the shopfloor was not always in the latest version, the handwritten SPC data was sometimes difficult to read, there would be delays in compiling data due to hand processing.
ATS implemented an SPC solution which enables the customer the capability to link data from the process lines with live quality & SPC analytics. SPC alarms offer management a more interactive role with the shopfloor, including a better collaboration with engineering and maintenance. Quality authorities are now informed of their quality progress in real-time from their offices analyzing Cp, Cpk …

In the customer’s words: “SPC has meant a new world for us, from basic handmade tools to advanced process control, integrated management of real-time and historical data and quicker resolution of problems since they are detected immediately by the operator.”

The implementation of the OEE module integrated within Ignition SCADA allows the plants to get a real time status of the production line. The addition with the ERP connectivity via the Web Services module, reduces the need of paper, allowing a more dynamic and real-time planning and control of the line. The integration with the PLC adds more accurate reasons for downtimes and timing.
With increased quality of information, management and maintenance can pinpoint and resolve issues more effectively. Various plants within the group now have the same standard way to record information and calculate OEE.
“Since the implementation of the OEE, we have improved the resolution of downtimes in the lines, acquired a better understanding of the line bottlenecks and reduced dramatically the paperwork.”

ATS implemented a system which offers to the customer the feature to track all the consumed materials and the produced serialized final product through the whole plant. Ignition and Sepasoft MES modules played a key part in this solution. Merging the SCADA features, ERP interface and MES modules in one single application, easy to use for the operators, was a strategic option for this customer. The system receives the Work Orders and Bill of Materials from their ERP. The operator scans the materials while using Ignition to verify the right information vs BOM. With the use of PLC, inline Barcode scanners, each ingredient is recorded and coordinated with their production context, offering to the customer a historical traceability downstream and upstream. This solution enforced the traceability and quality of the product, as well as the end customer trust.
“Since the implementation, we have improved a lot, the identification of the different Work in Progress materials, standardizing the label ID, we have a much better visibility over the material flows (real-time status) and traceability of products sent to each customer is now possible.”