Data Collection Project Profile
The Challenge:
A baby formula production plant had an outdated and expensive to maintain database, which limited data collection, making it difficult to analyze and improve the product.
What we did:
- Designed, developed and installed a SQL Database, resulting in being able to collect more data & easier analysis to make product changes more rapidly
- Created protocols for consistent installation and upgrades, which produces more consistent results
- Tested different versions of I/O drivers to determine the best fit and performance
- Ensured network performance wasn’t decreased by the new database
- Developed validation protocols for the software installation and data collection
- Performed check out, start-up commissioning and training to ensure project goals were met
How we did it:
Configured and installed a new system using Wonderware® IndustrialSQL Server™, Wonderware® I/O drivers & Wonderware® ActiveFactory™
- IndustrialSQL Server™
- Four remote IDAS and I/O driver servers
- Allen-Bradley I/O communicating via Ethernet
- Users access data using Microsoft Excel with the ActiveFactory™ add-ins
Food Processing OEM
The Challenge:
OEM was providing quality equipment without a control system. This left it up to the end user to source and install a control system, which could lead to inconsistent operation and equipment dissatisfaction and reduced product quality.
What we did:
- Designed, develop, and created controls systems for each equipment type
- Performed full check out of control panel prior to shipment to minimize field check out and verification of entire system, saving time
- Developed PLC and HMI code to ensure consistent and valid equipment operation
- Performed check out, start-up commissioning, and training to ensure project goals and customer satisfaction were met
Arc Flash Hazard Assessment
The Challenge:
A plastic film facility was issued OSHA citations for not having proper PPE or tools to protect their employees from electrical hazards, therefore endangering their lives.
What we did:
Put the plant in compliance with OSHA by conducting an Electrical Hazard Assessment, resulting in labeling all equipment with hazard risk categories and PPE needed to work on “live” electrical equipment, therefore protecting the electrical worker and surrounding co-workers.
How we did it:
- Performed an Electrical Hazard Analysis, collecting field data
- Produced and installed ARC Flash warning labels for each piece of equipment displaying the hazard risk category and PPE requirements
- Supplied a complete report with recommendations and findings and trained employees how to work electrically safe
Seed Corn Project Profile
The Challenge
A seed corn facility had operator error, resulting in different types of seed corn being mixed, which resulted in product waste.
What we did:
Designed, developed, installed and programmed a control system and SQL database to track product and prevent mixing
Developed production reports of critical process parameter information to reduce waste and improve quality
How we did it:
Configured and installed a new system using Wonderware® InTouch™, Wonderware® DAS Servers and Wonderware® Historian Client™
- IndustrialSQL Server™
- Redundant object and DAS servers with mirrored custom database
- Redundant Terminal Servers with thin clients
- Multiple PLCs communicating via Ethernet
- Users access data using Crystal Reports