Go (Recon)Figure
- Author George Zhookoff
- Published April 29, 2012
- Word count 710
In the manufacturing world, time is often your worst enemy. Margins are usually tight, and start-up schedules have to be as short as possible. This is especially true when it comes to large consumer goods companies. One such client recently wanted to replace packaging lines, and their success can largely be chalked up to solid virtual simulation and system analytics tools.
The situation was difficult: one of the world’s largest consumer goods company’s iconic food has been on the tables of millions of Americans for decades. However, new requirements for increased flexibility and capacity in the line demanded that the old line and control software be changed out. With a tight two-week deadline, the client needed to meet or exceed the following work requirements: Four banks of baggers with the ability to share common trunk lines, every bagger needed to be able to go to any packer, old lines and control software needed to be removed and replaced, completely dynamic controls debugging was needed in 2 days (not the standard 2-4 weeks), and they needed to be back in production 2 weeks from the day the line was shut down.
For the manufacturer to meet these deadlines and requirements, they had 3 options: Build the line off-site (pre-integrate) and then disassemble and reinstall, send production to outside co-packer for the duration of shutdown, or virtual pre-integration and virtual commissioning of controls.
Our team quickly eliminated the options to build the line off site, which would require disassembling it and reinstalling it. The time, complexity and costs made that option impractical. Also eliminated from consideration was to send production to an outside co-packer for the duration of the shutdown. Tight deadlines and margins, as well as costs, made that option untenable, as well. The team quickly shifted to performing a virtual pre-integration and virtual commissioning of controls.
The virtual verification followed a 4-step process prior to installing equipment and making the new line live: Audit; Develop Model/Create Process to Test Model; Develop New Program Control Scheme; Test on Model.
For the Audit step, each packaging line was audited prior to the beginning of the relocation to verify the accuracy of the layouts, schematics, programs and the system architecture. Each packaging line’s PLC and HMI programs were then recorded and used as a base point for simulation program development.
Next, checklists were developed for each control point to validate and verify the engineering of the relocation. With all those assurances regarding legacy data and performance in place, the simulation program development for the new line could begin. Emulation models allowed the controls engineers to validate all the custom code for a system using a scaled, 3D simulation of the line.
The consulting team set up the HMI & PLC at their lab in Atlanta. New control schemes were created; HMI screens were developed; and custom programming was written. New PLCs were to be integrated into the existing system architecture. The system also used a new HMI distributed application configuration allowing monitoring and servicing from a centralized location with the added benefit of being deployed to existing HMI locations as required.
Once the PLC and HMI programs were completed, they could be tested on the new simulation model. Dynamic checklists were developed and used to validate each possible routing scenario for baggers to cartoners. The dynamic checklists included the validation of fault logic, jam logic and routing capabilities with an emphasis of "on-demand" change-overs.
At this point, complete dynamic controls debugging could begin. Controls engineers executed and debugged the modified PLC and HMI programs prior to onsite commissioning. The team’s simulation and systems analytics tools were used to test, debug and confirm the control systems functionality of each routing scenario prior to on-site commissioning.
The customer then verified all systems analytics data, models and simulation during a demonstration of the controls at the office. The actual installation could start with the full confidence of the entire team.
The application of the simulation and systems analytics tools allowed the client to have their line up and running by the deadline. They also outran their startup curve. In fact, all requirements were met or exceeded. This was made possible only because the team made use of proprietary emulation modeling tools and startup management practices.
E2M helps customers engineer and operate with manufacturing excellence. The company is based in Duluth, Georgia, applying its project management and engineering expertise in hundreds of engagements with many of the world's largest Food, Beverage, Pharmaceutical, and Consumer Products companies since its founding in 1985. If you’d like more information about this topic, please call George Zhookoff at (678)328-2935, email him at George.Zhookoff@haskell.com, or visit us at http://www.e2m.com
Article source: https://articlebiz.comRate article
Article comments
There are no posted comments.
Related articles
- The Transformative Power of Yamaigel’s Certified Gel Eye Masks
- Checking account with cell phone protection!
- Keeping Cool This Summer: Air Conditioning Installation Services in Milwaukee
- A DIY Guide to Fixing Your Garage Door (with a Call to Garage Door Magnolia When All Else Fails!)
- Can a Bent Garage Door Be Bent Back into Shape? Don't Panic, Call Kiki Garage Door!
- How Can I Tell If My Garage Door Opener Sensor Is Bad?
- Maximizing Profitability: The Economics Behind Customizable Design Assets
- Exploring the Hidden Gems of Si Racha, Thailand
- DIY vs. Professional Movers: Pros and Cons in 2024
- MK Web Celebrates Top Position in Bourne's Premier Web Design Rankings
- The Road to Sobriety: Understanding Substance Use Disorders
- MotorKote Ultimate 40/60 Synthetic Hyper Mix 5W-30
- Exploring Denver on a Dime: A Frugal Travel Guide
- Top 10 Ways Production Scheduling in Business Central Transforms Manufacturing
- Strength Training and it's Incredible Benefits for Fat Burning
- Enhancing Home Security with Aluminum Shutters: A Focus on Weatherwell Elite
- 5 Easy Ways to Make Oral Hygiene Fun for the Whole Family
- Transforming Plastic Extrusion Machines into Recycling Powerhouses
- Unraveling the Potential of Plastic Extrusion Machines
- The Rise of Plastic Recycling Machines: A Step Towards Sustainability
- Strawberry Cheesecake Ice Cream: OMG! Unreal!
- The Advantages of Using Professional Home Cleaners in Ilford
- 8 Compelling Reasons to Hire Professional Home Cleaners
- The 12 Steps Narcotics Anonymous Program To Recovery
- Send Money to Tanzania: Effortless Transfers with SafariRemit
- Stylish Savings: 10 Frugal Ways to Stay Fashionable in 2024
- Fly Cheap With FlightPapa To Any City
- How Collaborating with a Software Development Company Can Propel Your Business Forward
- A Comprehensive Guide to Choosing the Best Hair Transplant Method
- 15 Frugal Tips for a Memorable Wedding Day