Plant Integration and MES Solution for Industry
14 likes•6,775 views
The document outlines a modular solution framework for various industries, particularly focusing on manufacturing, energy, and pharmaceuticals, offering integration of plant control systems with MES, SAP, and ERP solutions. It emphasizes effective data acquisition and communication among different equipment to enhance operational efficiency, reduce downtime, and improve productivity metrics like OEE. Additionally, the document presents a value proposition that highlights global experience, technical prowess, and a dedicated consulting team to aid in implementing these technological solutions.
Plant Integration and MES Solution for Industry
- 1. MES Solution Framework Food & Beverages Metals & Mining / Cement Life Science & Pharmaceutical Oil & Gas Manufacturing Chemical Energy & Power Infrastructure & Utility 1 Contact: Sunil Wadhwa
- 2. Our Solutions & Services SAP MII MES, Batching MIS, LIMS Software development SCADA, DCS PLC, Drives, Safety Systems Instrumentation & Electrical Engineering Manufacturing Pharma & Life Sciences O & G/ Petrochemical Energy & Power FMCG Metal & Mining Utilities HVAC & BMS Chemicals 2 Contact: Sunil Wadhwa
- 3. • Comprehensive, Yet Modular Solution • Single Integrated Plant IT Infrastructure – Easy to Maintain & Upgrade Plant Intelligence Solutions - Unique Architecture SAP MII Connector Business System–SAP/ ERP Solution Map MES Preparedness MES SAP Integration 3 Contact: Sunil Wadhwa
- 4. • Communication enablement of Existing PLC/ CNC/ Robots/ Controller/HMI/Bar- Code Reader/ Vision Camera/ Weigh Scale/DCS with required engineering for connecting to MES • Complete solution from As-IS Study to Add-on Hardware Supply, PLC/CNC/HMI/ Robot program modifications, network design, tag level engineering, mapping with MES database, OPC enablement.. Single OPC connection for MES system • Central Data collection from disparate PLC/control systems/Equipment pertaining to process parameters. • Data Acquisition as per required Speed, Scaling, Tags, etc in order to facilitate MES • A building block for building MES solution with/without data collection & reporting solution MES Preparedness/OPC enablement 4 Contact: Sunil Wadhwa
- 5. • Taking data/parameters from individual CNC machines which are available in the programming of that machines. (most essential) • Information of currently running process and product in individual machines. • Calculating the OEE of individual machines and complete line as well. • All data accessible to all concern authority through wireless /LAN media • Troubleshooting and route cause analysis to reduce the downtime • Tracking of changes made in programming • Verification of programming /schedule about to load next in the machine • Automatic management of Production Batches What it means for your Machines / Assembly Line? 5 Contact: Sunil Wadhwa
- 6. Typical System Architecture- MES preparedness 6 Contact: Sunil Wadhwa Central OPC Server PLC-N Serial to Ethernet Converter Ethernet Network HMI- PLC connection Ethernet Network Serial Network SCADA HMI HMI PLC-1 PLC-2 PLC-3 PLC Add- on card Ethernet Network CNC -1 to NRobots-1 To N
- 7. HMI/SCADA, Batch, PPS, Tracker SOA&Workflow DataMart Control & IO Portal(RTIP) SAP, Oracle, Microsoft Dynamics, etc. Historian SharePoint,BO,Etc.. Plant Apps Production Tracking Quality Management Efficiency Management Schedule Execution Genealogy Traceability Energy Management Environmental Management ManufacturingIntelligence Manufacturing Execution & Performance Management WebSpace(ThinflexibleGUI) Manual Work Processes Enterprise Resource Planning ERP, PLM, SAP MII “plant apps” Condition-based Maintenance Scheduling Troubleshooting BusinessIntelligence CollaborativeProductionManagement Proficy Product / Solution Map 7 Contact: Sunil Wadhwa
- 8. OEE Summary – Downtime Distribution The Downtime Distribution Dashboard displays the total “Pkg 1” Downtime based on Fault Code. 8 Contact: Sunil Wadhwa
- 9. OEE Summary Dashboard An “OEE Summary Dashboard” is available for real-time display of OEE values via a web browser. This type of report (combined with other KPI information) is ideal for use in Overview Dashboards monitored by corporate personnel. 9 Contact: Sunil Wadhwa
- 10. Our Value Proposition • Local presence with Global experience – Global Delivery Model • Preferred VAR and Implementation Partners • Leading Engineering & Software Solutions provider • Technical know-how on Latest and Legacy systems of - Major Automation Supplier’s Siemens, Rockwell, GE-Fanuc, Emerson, ABB, Honeywell, YBL etc • Comprehensive knowledge and rich experience in Plant Intelligence Solutions & Industrial Automation Technology in Level 1, 2, 3 & 4 – SCADA/Historian/Batch/LIMS/MES/SAP-MII/Homegrown data base • Sector Know how – Manufacturing, Factory Automation, FMCG, Pharma, etc. • Dedicated Solution Practice – 50+ consultants… • Proven Project Management Model • Rich experience in similar solution in CPG industry 10 Contact: Sunil Wadhwa
- 11. Benefit Realization on ROA & ROI Integration of Plant Control System with MIS, MES, ERP Productivity & OEE Gains Enterprise Resource Planning ERP, PLM Connected Systems – PLC, CNC, HMI, Robots, SCADA & DCS MIS – Real Time Plant Data Integration, Analytics of Mfg Processes, Improved Visibility of Plant Data Disparate & Non- Standard Control Systems, No Connectivity, No Visibility of Plant Data & Lots of Bottlenecks, High Maint Cost ReturnonAssets&Investment### Manufacturing Execution, Oper ations & Performance Management, Geneology, etc. Note: ###The data used above is only for indicative purpose based on general observations in industry. The actuals gains could be different based on real implementation of system and nature of plant/process/ industry.
- 12. THANK YOU 12© May 2014. All trademarks and products mentioned in this presentation are properties of their respective owners.
Editor's Notes
- #8: This is carefully thought out