YPÊ Cleans Up Production with PlantPAx System and MES

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Cleaning Up Production with PlantPAx and MES Ypê - Brazil

Cláudio Fernando de Jesus

Ypê – Innovation Manager

[email protected]

Rafael Pezzella Chiea

Iastech – Sales Manager

[email protected]

November 17-18, 2014


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Ypê Anapolis / Brazil – A Dream


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Agenda

Conclusions

The Project

The Automation

The New Plant

Ypê & Iastech


#PSUG

IASTECH

Since 1990

Rockwell Automation Solution Partner

Quality System - ISO 9001:2008

EPM and PMI

More than 1800 projects

Life science, food and beverage, chemical specialist

Rockwell Automation Solution Partner since the beginning of the program ! Rockwell Automation Process Solution Provider !

Rockwell Automation Information Solution !


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Ypê

Since 1950, Ypê is a 100% Brazilian

Company dedicated to make

household products.

Leader company in the laundry soap,

dishwashing liquid detergent and

liquid softener segments.

Other products: bath soap bar, powdered

detergent, laundry detergent, steel wool pads,

multi surface cleaner, scrub sponge.


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Ypê - HPC Product Lines


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Agenda

Conclusions

The Project

The Automation

The New Plant

Ypê & Iastech


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The New Plant – Our Challenges

Quick project turnaround

Totally integrated with ERP system

Levels 0, 1 and 2 – totally integrated

Scalability

High availability

Full remote access

Security


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The New Plant: Main Core with MES and PlantPAx Integration System


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The New Plant: Process Overview


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Agenda

Conclusions

The Project

The Automation

The New Plant

Ypê & Iastech


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Corporate Management

SAP ERP

The New Plant: Integrating Levels


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MES (Manufacturing Execution System) SCADA Server


SAP ERP

View Point

HMI Server

Redundant HMI/Data Server

Data Server

HP Proliant BL460C

05 physical computers 09 virtual

computers

Transaction Historian

FT Directory

Engineering FT View Studio


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Automation Process

Plant Floor




SAP ERP Client 1

EKI-7656C SW001

Deposito

EKI-7656C SW002

Caldeira

EKI-7656C SW003

Processo

EKI-7656C SW004

Det. L1

EKI-7656C SW005

Det. L2

EKI-7656C SW006

Ama. L1

EKI-7656C SW007

Ama. L2

EKI-7656C SW008

Ama. L3

Pos.

Ench.

Etiq.

Enca.

Pale.

Pos.

Ench.

Etiq.

Enca.

Pale.

Ench.

Enca.

Ench.

Enca.

Ench.

Enca.

Client 2

Client 3

Ethernet TCP/IP

Flow meter

Ethernet/IP

Pressure

4...20mA / Hart Inverter

DeviceNet

Weight System

DeviceNet

Temperature

4...20mA / Hart

Conductivity

4…20mA / Hart


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Automation Process

Plant Floor

The New Plant: All Integrated Levels



SAP ERP


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The New Plant: Preparation Automation Hardware Overview

Process Control

Mixer 01 Mixer 02 Mixer 03

Dosing Unit

Mixer 01 Mixer 02 Mixer 03

Dosing Unit

Liquid Detergent Liquid Softner

Utilities Pharmacy Silo

ControlNet_1

Client 01 Client 02


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The project: Preparation Automation Hardware Architecture

ControlLogix 5562 CPU

(4 MB)

352

336

48

16 20

ControlNet 1 I/O’s

DI

DO

AI

AI (Hart)

AO

RmCn Torre 2

RmCn Utilidades

RmCn R1 Deterg.

RmCn R2 Deterg.

RmCn A1 Amac.

RmCn A2 Amac.

RmCn L3 Amac.

RmCn R3 Deterg.

RmCn Torre 1

RmCn Dosador D.

RmCn Dosador A.

RmCn Farmácia


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The project: Preparation Automation Hardware Architecture

DeviceNet 2:

08 x POWERFLEX 753

Preparation CCM

DeviceNet 1:

14 x POWERFLEX 753

Utilities CCM

DeviceNet 3:

10 x Alfa 2710D - 2 Channels

Weight System


(4 MB)


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The New Plant: Storage Automation Hardware Overview

Storage Control

Unit 01 Unit 02

Desmineralized Water

Remote 02

Remote 01

Storage Remotes

Remote 03

Manifold Remotes

Line 01 Line 02

Line 01 Line 02

Liquid Detergent

Line 03

Liquid Softener

Main

ControlNet_2 ControlNet_1


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The project: Storage Automation Hardware Architecture

RmCn Depósito1

RmCn Descarreg.

RmCn L1 Deterg.

RmCn L2 Deterg.

RmCn L1 Amac.

RmCn L2 Amac.

RmCn L3 Amac.

RmCn Manifold

RmCn Desmi1

RmCn Desmi2

RmCn Depósito2

RmCn Depósito3

128

96

0

80

0


DIDOAIAI (Hart)AO

232

200

4 64

0


DIDOAIAI (Hart)AO


(4 MB)


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The project: Storage Automation Hardware Architecture

DeviceNet 2: 13 x POWERFLEX 753 End Product Storage CCM

DeviceNet 1: 25 x POWERFLEX 753 Raw Material CCM


(4 MB)


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The New Plant: Filler Lines Automation Hardware Overview

Line 01

Liquid Detergent

Line 02

Line 01

Liquid Softener

Line 02

Line 03


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The project: Filler Lines Automation Hardware Architecture

CompactLogix L35E CPU (1,5 MB)

Filler Line CCM

DeviceNet 1: 12 x POWERFLEX 40

64 32

8 8

Local I/O’s

DI

DO

AI

AI (Hart)

AO


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The project: Filler Lines Automation Hardware Architecture

For Five Filler Lines

320 160

40 40

Local I/O’s

DI

DO

AI

AI (Hart)

AO

60 x POWERFLEX 40


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The project: Totalized Hardware Numbers

CONTROLLERS, NETWORKS AND EQUIPMENTS.

1032

792

92 160 60 Totalized I/O’s

DI

DO

AI

AI (Hart)

AO

2 x ControlLogix

5562 CPU (4 MB)

5 x CompactLogix

L35E CPU (1,5 MB)

DeviceNet

10 x DeviceNet

ControlNet

3 x ControlNet

60 x POWERFLEX 40

60 x POWERFLEX 753

10 x Alfa 2710D

2 Channels Weight

System


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The project: Software SCADA / MES

PROCESS AUTOMATION SYSTEM SERVER - PASS

1 x FactoryTalk View Site Edition Server 100 Display with RSLinx; 9701-VWSS100LENE

11 x FactoryTalk View Site Edition Client 9701-VWSCWAENE

1 x FactoryTalk VantagePoint 9521-VPCL03ENE

1 x FactoryTalk Historian Site Edition 9518-HSERA1K

1 x FactoryTalk ViewPoint 9522VWP03RENE

MSSQL

1 x MSSQL2008 Standard


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PlantPAx – Liquid Detergent Preparation Screen Shots


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PlantPAx – Liquid Softener Preparation Screen Shots


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PlantPAx – Storage Screen Shots


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PlantPAx – Air, Water and Pharmacy Utilities Screen Shots


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PlantPAx – Desmineralized Water Screen Shots


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PlantPAx – Filler Lines Screen Shots


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PlantPAx – FactoryTalk Historian Screen Shots


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PlantPAx – MES Screen Shots


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Production Reports

Production Times

Dosage Deviations

Level of Storage Tanks Raw Material and End Products

Inventory Control

WEB SCADA Application

Audit Trail

SAP System Orders Control


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PlantPAx – FT ViewPoint Screen Shots


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PlantPAx – SAP / MES / SCADA Overview


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PlantPAx – SAP / MES / SCADA Integration Screen Shots


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PlantPAx – SAP / MES / SCADA Integration Screen Shots


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PlantPAx – SAP / MES / SCADA Integration Messages and Interfaces

Get sample to send to the Quality Control

Warning! There are corrective measures for this batch.

Waiting end of corrective measures for this batch.

Waiting end of analyses of corrective measures for

this batch.

Interface to operate the corrective measures.


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Batch Successfully finalized.

Do You want report consumptions for SAP System?

Batch finalized with corrections.

Please call your supervisor to report consumptions

for SAP System?

Batch finalized with corrections.

Do You want report consumptions for SAP System?

Batch approved!

Do You want to move the balance?

Waiting status available for use from SAP System to

initiate transfer.


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Agenda

Conclusions

The Project

The Automation

The New Plant

Ypê & Iastech


#PSUG

Main Project Phases

Process

Process Definition;

Process Description;

Batch recipes description;

Operation Analyses;

Functional Specification;

Operation Design;

Automation

Hardware Design Specification;

Control Architecture design;

Control Software Programming;

Factory Acceptance Tests with process

simulation – FAT.


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Main Project Phases

Plant Construction (12 months in total);

Electrical panels and hardware (3 months);

Specifications, Software and FAT (3 months);

I/O test (15 days);

Batch and recipes test (20 days);

Commissioning and Start-up (30 days);

Site Acceptance Tests – SAT;

Operator Training - Operation Tests;

Assisted Operation.


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Agenda

Conclusions

The Project

The Automation

The New Plant

Ypê & Iastech


#PSUG

Achievements

With this project:

High system reliability;

Full integration with SAP System (MM, QM, PP);

Control over production orders;

Operator can control the whole process;

Historical data and Audit Trail;

Process reports and real time calculations;

High efficiency process;

Easy automation diagnosis and maintenance.


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Teamwork

IASTECH Gestão e Automação Industrial


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Ypê Anapolis / Brazil – From Dream to Real Plant


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Questions

Cláudio Fernando de Jesus

Ypê – Innovation Manager

[email protected]

Rafael Pezzella Chiea

Iastech – Sales Manager

[email protected]

November 17-18, 2014

Technology

YPÊ Cleans Up Production with PlantPAx System and MES