Case Studies Archive - Opensoft Systems Ltd

Food Manufacturer – MES / ERP Integration

Opensoft Systems Ltd — Tue, 02 Nov 2021 17:46:56 +0000

SAP Integration with Blending Plant MES systems

Our client is a food manufacturing company that supplies thousands of food ingredients to customers in more than 150 countries worldwide. One area of the company makes dried ingredients (e.g., dry sauce blend, powder seasoning, etc.), for their own brands as well as for popular high street and supermarkets brands. It is in this area that our client engaged Opensoft Systems to carry out an SAP Integration to their Blending Plant MES systems.

Click here to learn about MES ERP Integration Service

The Challenge

Our client blends tons of dried ingredients daily, handling hundreds of recipes specific to their customers’ requirements, most of these recipes using flour as the main ingredients.

Their factory floor has three areas. They are:

Flour mill
Storage area where individual ingredients are stored
Blending plant
Packaging
Goods Despatch

Their production process flows as follows:

Flour and ingredients are sent to the blending vessels for mixing, they are then discharged from the mixing vessels, bagged, barcoded and sent to the warehouse ready for dispatch.

Original Architecture

When planning each schedule, they must consider the manufacturing priority of each order to ensure efficient planning and manufacturing execution. This means ensuring that the correct time duration for carrying out the Clean in Process (CIP) is factored in within each production run. CIP eliminates cross contamination across batches, so it is essential in the production process.

Our client uses SAP as their ERP system for their resource and planning; this was not integrated to their plant manufacturing execution systems, resulting in an entirely manual process. They have to physically print off each production order and prioritise them dependent on batch type, recipe, and volume. Production requests are then sent via a manual production order request where the orders were collated by the production staff and re-inputted into a production spreadsheet log.

Since there is no integration between SAP and MES, orders were passed to the production department at the end of each day, which meant the production manager could only plan the schedule one day at a time, wasting time and resources. This led to more raw materials (flour) being requested from the mill than was needed by the recipe, resulting in a stock being re-worked within the Blending plant.

Our client recognized that this was not the most efficient use of resources which resulted in the need to streamline and automate the production process.

Screen showing list of recipes associated with the order.

The Proposal

Opensoft Systems were asked to conduct a site audit of the production plant’s existing PLC and SCADA systems. During which Opensoft Systems senior engineers met with all stakeholders, including the production planning, supply chain, production, and the engineering team. We jointly agreed the main objectives for the project:

To effectively schedule each day’s production plan in the most efficient way and to minimise cross-contamination from colours, flavours, and allergens.
To efficiently schedule the base ingredients to eliminate surplus and avoid rework.
Avoid the re-keying of production recipe data and eliminate data entry errors.
Provide a live status production update to the ERP system

To achieve the objectives, Opensoft Systems proposed the following:

Categorise each ingredient depending on their contamination risk (e.g.: clean, colour, flavour, etc.)
Decide the minimum number of days that should be planned at one time, allowing for the need to reschedule to take into account fast-tracked orders.
Design a method to reposition the jobs in the plan and add the ability to reschedule a new running order, adding in the clean in-process procedure as required to avoid contamination.
Integrate SAP to the MES System to enable the end-to-end integration of batch production orders to the production facility. This was to provide a live view of any in-process production batch order and provide an update to the raw ingredients inventory.
To provide user access to the system using a ‘zero client’ approach, effectively providing thin clients with web browser access via the company’s intranet. This allowed users to plan, schedule, execute and view all production batches across the factory.

The Solution

Opensoft Systems designed and built the new system architecture and integrated it to their SAP system. As a result, when an order is now released in SAP, the batch request data automatically transfers to the MES, and the real-time status for each batch is displayed in the production schedule held within the MES application.

After computing variables, we provided within the application, the system presents the production operator with a suggested schedule plan based on the orders size, volume, priority, and ingredient make up. The operator has an option to accept or modify the schedule. Once the schedule plan is accepted, the order is updated with the processing time and expected dispatch date. Production batches are then committed to production.

Our client now has visibility of their entire process from order confirmation to dispatch date. Since the sales team can see the production process in real-time, they can manage their customers’ expectations regarding order fulfillment. The customer service team can quickly give updates regarding order status. Additionally, the new system produces a batch trail report which they can use to prove compliance to food standard policies.

Client's Feedback

‘We are very pleased with result of this project. A month after the project was completed, we were audited by one of our major customers for food compliance. We were worried as the system was still settling down. However, we are pleased to say that we passed the audit first time. Our plants efficiency is now on average, 40% higher per month due to the improvements made to our production system.’

Production Manager

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Cheese Production – SCADA / Virtualisation

Opensoft Systems Ltd — Mon, 04 Oct 2021 09:41:10 +0000

Virtual SCADA Deployment

Our client is a manufacturer of award-winning cheese and some of the most recognisable brands of cheeses available in the market. They are one of the largest producers of cheddar in the UK.

More information about Virtualisation

The Challenge

Our client’s site production system responsible for the dairy process was deployed over 15 years ago. Their existing SCADA is installed in a traditional PC located in the reception area and cheese production area. As cheese making process involves heating cheese vats by steam, humidity is a constant challenge in the factory.

The humidity is causing condensation. The constant damp is damaging their PC’s components, causing them to short-circuit and fail. When this happens, they lose their data, and production stops while they replace the PC and rebuild their system.

Following several system failures that affected their production, their group automation engineer approached Opensoft Systems to address the issue. One vital part of their brief is for Opensoft Systems to design a system with a solution based on their current SCADA platform and to factor in future expansion plans.

The Solution

Following the initial consultation, we proposed the following solution:

Virtualise their existing system to build resilience.
Keep the virtual server in an air-conditioned room in a different location within the plant, where condensation is not a problem.
Build active redundancy to increase system reliability

The process was split into two phases. Phase 1 is virtualising their existing system, and phase 2 is upgrading their SCADA in the virtual platform. We also proposed to keep their existing S7-400 PLC as they are in good order.

The Implementation

Opensoft Systems took a copy of our client’s existing system and upload them to the virtual machine server that is now located in a different area with controlled temperature. We upgraded their PLC communication to Ethernet to enable radio frequency detection with auto switch-over to the standby server in the event of system failure.

This means that one system fails, the virtual machines running on it will move to the other server and start automatically.

To remove the risk of local PC failure, we deployed thin client technology to access the server. As thin clients have no hard drive and operating system, they are resilient to dampness. And if they fail, they can be easily replaced without affecting the data.

The virtualised environment now provides fully automatic failover in case of system failures.

This provides the plant with a redundant system that is extremely quick to rebuild when required. A fully built client can be configured as a master template and redeploy within minutes.

Our client’s system is also now easily scaled. If they want to expand their system, they simply need to add more thin clients and connect them to the server. If they need to install new software, patch an application or operating system, or upgrade their network, they only need to do the work on the server, not on an individual terminal.

Client's Original Architecture

Client's Feedback

‘Since the new system was installed, it has performed more smoothly with the added safeguard that our SCADA is now fully redundant. We can expand the system as required without unnecessary system build time. With thin clients, we don’t need extra PCs across the plant, which in the past, have become an additional maintenance overhead for us.

The installation was seamless and didn’t cause disruption to the plant’.

Group Automation Engineer

Client's New Architecture

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Brewing – PLC / SCADA Integration

Opensoft Systems Ltd — Fri, 24 Sep 2021 15:02:51 +0000

Network and PLC Upgrade for Process Evaporator

Heineken is one of UK’s most recognisable cider and beer brands, as well as the company behind some of the popular brands such as Strongbow and Foster’s. The company has a number of production plants in the country. Recently, Opensoft Systems was tasked to carry out a control systems upgrade on their process evaporator at their cider production plant that produces their cider portfolio, including Strongbow and Bulmers.

Click here to visit Heinken’s website

The Challenge

The Universal Beverages Ledbury manufacturing site has an important role in the production of Heineken beer and cider. The site processes some 130,000 tonnes of apples at the site every year. The control system across the plant consists of the main PLC communicating through a DeviceNet network to six other remote racks, and connected to a single SCADA system. The existing PLC is past its lifecycle and needs upgrading. The remote 1794-ASB flex I/O racks were also obsolete and unsupported and the DeviceNet network had been experiencing network faults.

The Proposal

To upgrade the plant’s system, Opensoft proposed to migrate their existing Rockwell PLC 5 series rack to a Rockwell Controllogix rack and replace the DeviceNet ring topology network with an Ethernet ring topology network.

The Solution

Before starting on the proposed solution, HEINEKEN and Opensoft Systems Engineering Teams worked together to develop a Functional Design Specification (FDS) to ensure that everyone involved is clear about their roles and responsibilities in the project. After HEINEKEN has signed off the FDS, the project was commissioned with minimal disruption to the production process. The new control system now provides stability to a critical part of the production process ensuring future supportability.

Technologies Used

Rockwell Control Logix 1756-L71 – 1794-ASB flex I/O racks

SCADA software

Original System Configuration

Client's Feedback

“We have now run all of the production processes and CIP recipes without many major problems and the machine is efficiently producing concentrate. All in all a very successful piece of work without any problems. Thanks to all of your colleagues at Opensoft who worked on this project.”

Site Automation Manager

Heineken

New System Configuration

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Waste Management – Anaerobic Digestion / Control & Optimisation Project

admin — Wed, 08 Sep 2021 10:03:21 +0000

Anaerobic Digestion Strain Press Modifications and SCADA Re-integration For Existing System

Biffa is the second-largest UK based waste management company and provides household collection, landfill, recycling and special waste management services to local authorities as well as industrial and commercial customers in the UK. Opensoft Systems have been engaged with Biffa since April 2017 for Plant Automation Solutions and Support Services for the Anaerobic Digestion Process Plant.

Click here to visit Biffa website

The Challenge

In order to handle a wider variety of waste contaminated with waste plastics, Biffa recognised the need to implement modifications to their process machinery to enable the plant to handle new material. Biffa approached Opensoft Systems to carry out the control changes required to the Strain Press Equipment, integral to the handling of this waste stream.

The Proposal

Additional tags were created and templates modified for the additional screens within the sites Cimplicity SCADA application. An additional static screen was created for the Strain Press Machines. Strain Press dynamic linking was developed and a faceplate created for the Strain Press operation. The decanters screen was then modified and the decanters screen dynamically linked. Several other navigation screens from the decanters to the Strain Press needed to be modified.

The Solution

Two new strain press machines were commissioned at the facility within the dewatering plant, re-directing Digester liquor into the strain presses prior to being pumped back into the sites existing decanters.

The resulting changes in the process involved the redesign to the SCADA Graphic screens to reflect the physical changes made to the plant by introduction of the new equipment. This would ensure that plant operators had a clear view of all process equipment and the process as a whole.

The existing Siemens S7-400 PLC code was modified to enable the changes in the control of the new plant, this involved the introduction of new code and changes to the existing code structure.

Digester Architecture

Client's Feedback

‘I am pleased with how this project has progressed.

From start to finish the objectives were well defined and the documentation supporting our project has been first class. A number of long-standing communications issues on our network caused some problems along the way, however these were handled expertly as encountered by the Opensoft team and the project brought to a successful conclusion.

Thank you to all involved with this project’

Site Electrical Engineering Manager

Biffa

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Air Separation Producer – Major Automation Project

Opensoft Systems Ltd — Wed, 01 Sep 2021 13:06:01 +0000

Upgrade of ageing hardware & operating systems

Air Liquide UK provides a wide range of cylinder gases utilised across a wide range of industries from Brewing, Food processing to Healthcare and Pharmaceutical applications.

Click here to visit Air Liquide website

The Challenge

The company approached Opensoft Systems to assist with an ageing control system on one of their continuous gas production facilities.

The Solution

A virtual solution was deployed to enable the replacement of existing ageing hardware and operating systems to a more supportable platform. As the operation demanded close control and visualisation of the process by operators 24 hours per day 7 days a week, a failover facility was implemented to ensure continuous monitoring and control of the production process in the event of the primary SCADA system failing. The sites production batch records and applications are configured automatically to be securely backed up to the sites backup server to further safe guard the sites assets.

Customer Feedback

“We recently commissioned Opensoft Systems to provide us with greater resilience in our main control system.

The system is critical to our site operations and the continuous production of CO2.

They implemented the required engineering modifications across our SCADA and PLC systems swiftly and professionally,the system now provides the added security which we require for our round the clock operations.

Their engineers were punctual, highly knowledgeable and very professional at all times, ensuring a smooth transition.”

Air Liquide

UK Primary Process Plant Manager

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Brick Manufacturer – Data Collection & Reporting

Opensoft Systems Ltd — Fri, 13 Aug 2021 09:53:15 +0000

Brick Manufacturer – Operational Performance

Ibstock is the UK’s leading manufacturer by volume of clay bricks sold and offers a wide range of clay-facing bricks. The company operates 19 factories across the country using a wide diversity of clays and manufacturing techniques.

Click here to visit IBSTOCK|BRICK website

The Challenge

Ibstock’s Aldridge site in the West Midlands had experienced a number of ‘after the event occurrences’, where operational difficulties had been encountered and led to valuable production losses. Ibstock approached Opensoft Systems to look for a solution to provide plant data from the site’s extensive PLCs (programmable logic controllers). The aim was to collect key production data on a continuous real-time basis to help drive continuous improvements in these areas.

The Proposal

To address the problem, Opensoft Systems proposed an industrial data historian implementation that will enable real-time collection of all defined plant data. Unlike conventional relational databases, the industrial data historian is capable of processing a high volume of data at high speed. This facilitates quick access to plant data using open database standards. This will enable the operations staff to quickly retrieve data from any period of time, allowing them to go back in time to analyse plant issues and get a greater understanding of faults so they can address them.

To ensure that the proposed solution addressed the site’s requirements, Opensoft Systems conducted a site audit before the start of the project to get a detailed appraisal of the site’s systems. The audit took into areas of interest, PLCs, and the volume of data in each area. Our team also reviewed the caballing required for the implementation.

The Solution

Opensoft installed an Industrial Data Historian to enable the real-time collection of all defined plant data and made key performance indicators (KPI’s) visible to all operational staff across all areas of the plant. This was done by steaming ‘live’ performance data to a series of dashboards providing operations staff with a real-time view of their production environment. Opensoft systems also adapted the dashboard to the exact requirements on-site to ensure the operations staff are monitoring key variables.

The dashboard connects to the historian and reads incoming data within the Runtime database, this, in turn, outputs the result to the dashboard for display on monitor displays around the site using thin clients which are run a standard Internet Explorer web browser.

Historian Real-Time Trend Display

Client's Feedback

‘Since implementing the system it has provided us with real-time insight into the factory’s status at any point in time. This has enabled us to react quickly to downtime situations and given us the ability to better understand faults to help drive improvements.

The historian provides an extremely useful feature in giving us the ability to better analyse past faults and understand the root cause.

Factory Manager

IBSTOCK|BRICK

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Waste Management – Energy from Waste / Data Reporting

Opensoft Systems Ltd — Sun, 08 Aug 2021 15:55:03 +0000

CEMS Reporting & CBIS Data Integration to Plant SCADA

Veolia is one of UK’s leading providers of comprehensive range of waste, water, and energy management services designed to build the circular economy and preserve scarce raw materials. It is one of the ‘Big Five’ waste management companies in the UK.

Click here to visit Veolia website

The Project

Veolia’s Energy Recovery Facility (ERF) in Sheffield is designed to handle 225,000 tonnes of solid waste a year. It generates up to 21MW of electricity to the National Grid, enough to power more than 25,000 homes.

Veolia uses Continuous Emissions Monitoring System (CEMS) at the plant to ensure it continues to conform with its emissions responsibilities specified by the Environment Agency under the plant’s permit to operate.

The Challenge

Veolia commissioned Opensoft Systems to provide their site with automated reporting for the sites stack emissions. The Reports were required on a real-time basis, with a daily summary report to provide regulatory compliance.

The Proposal

Opensoft proposed that the clients identify specific information they want to see in their report, this was in turn related to the regulatory requirements required by the Environment Agency.

Once requirements were clearly detailed, we worked in partnership with installers of the instruments installed in the stack to ensure signals generated were calibrated correctly at source and that the scaling calculations were applied correctly.

Our proposal then involved providing real-time emission reporting and a secure means of data storage of the collated values to protect against data loss resulting from IT failure.

The Solution

For this project, Opensoft used Proficy Historian, GE’s high-performance data archiving system that collects, efficiently and securely store, retrieve, distribute time-based data at high speed.

The project was completed in three phases. For the initial Phase, our engineer undertook at an Audit of the required process systems, collating information and running through reporting requirements with key stakeholders on site. This allowed the User & Functional Requirements (FDS) to be accurately determined. Phase 2. Once approved by the the client development work was undertaken offsite and the solution taken through internal component Testing at Opensoft’s offices.

Phase 3. The client carried out Factory Acceptance Testing (FAT) to verify the system against the specification and that the system responded as required. Once the system was taken to site the system was commissioned and Site Acceptance Testing undertaken against the specification design.

Client Feedback

“Opensoft worked well with our Emissions Monitoring Consultants to ensure the values being generated from the analyzers in the stack were accurately reflected in our CEM’s report. The result was a well, executed project which started with correct alignment of our requirements from the outset. Thank you to all involved.”

Veolia, Operations Manager

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Automotive – Off Road Equipment / SCADA & PLC Project

Opensoft Systems Ltd — Fri, 09 Jul 2021 08:17:32 +0000

SCADA System Development

Titan Steel Wheels located near Kidderminster, Worcestershire manufactures vehicle wheels for a wide variety of off-the-road equipment which includes earthmoving, construction and mining sector vehicles.

Click here to visit Titan website

The Challenge

Opensoft Systems were approached to take a look at their control system within their Electrophoretic Paint Facility. The operation had a legacy SCADA system that monitors the paint facility process.

The original installation was carried out in the mid-’90s, the SCADA operating system was running on a Windows 95 operating system, which has long since been obsolete.

This then communicated with an Allen Bradley PLC5 which although still functioning well, is now obsolete and was connected by Serial Communications rather than Ethernet.

The SCADA system hardware had started to fail more recently, resulting in the inability to recover the system to a bootable state. This led to an inability to monitor the process by the operators and quality team resulting in quality issues leading to re-work within the process.

The SCADA could not be migrated to a virtualised environment due to corruption caused by Multiple re-boots of the system.

The Proposal

Opensoft systems proposed to re-develop the application using updated SCADA software and integrate it into the existing PLC 5 hardware.

The Solution

Opensoft Systems delivered a Functional Design Specification (FDS) and redeveloped the SCADA using the new application while keeping the same look and feel of the existing Mimics and functionality.

The SCADA system was upgraded to the latest version and deployed on a modern PC running a Windows 10 Operating System.

During the commissioning of the system, the SCADA communications were established by configuring an OPC Server within SCADA to an RSLinx gateway. The interface was then connected to the original PLC using an RSLinx gateway and a Rockwell USB Network adapter.

Original Screen Button Layout

Client's Feedback

“In updating the top end SCADA system and leaving the original PLC in place, Opensoft Systems were able to deliver and deploy a solution that was not only cost-effective but practical too. We are very happy with the recent project.”

Production Engineering Manager

Titan Steel Wheels

New Screen Button Layout

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Superalloy Manufacturer – HMI & PLC Development

Opensoft Systems Ltd — Thu, 08 Jul 2021 16:16:35 +0000

HMI Solution for World Leading Superalloy Manufacturer

Ross & Catherall Ltd, are world leaders in the manufacture and supply of vacuum and air melted ferrous, nickel, and cobalt-base alloy barstock. Their products are utilised for turbine blades for aero engines and large land-based gas turbines, hot-end turbocharger wheels, and medical implants.

Click here to visit Doncaster Alloys website

The Challenge

Site Engineering asked Opensoft if they would investigate a HMI (Human Machine Interface) screen on site that was giving cause for concern. The HMI was on a grinding process that allows “billets” to be ground into pre-set sizes during the manufacturing process, a vital part of the production processing on site.

The existing HMI application was still operational, however, the aged and damaged screen was making it difficult for the operators to see the screen details accurately and prevented modifications being made to the HMI program when setup adjustments were required. Certain pre-set, set-points could not be selected on the HMI and a shift supervisor then had to override the panel to enable a selection, this took additional time and led to production delays.

To complicate matters further a traditional and straight-forward HMI upgrade was not going to be possible as the original HMI and HMI software were both obsolete and unsupportable, the software code being originally developed in German. The backup program files could not be loaded directly into a new HMI because the programming software was now obsolete, resulting in some redevelopment work being required.

Our Solution

Opensoft engineers arrived on site meticulously photographed and documented all cable and connection points associated with the damaged HMI taking a backup of the connected PLC.

Photographs were taken of all HMI screens, 63 windows, 712 tags, 75 event messages and 34 Graphic list screens.

The Outcome

Opensoft developed an FDS (Functional Design Specification) after the electrical drawing has been studied and code detailed. This allowed the original HMI code and functionality to be compared, any obsolete functionality and set-points were removed, replaced and updated as necessary. The graphical screens were also updated and upgraded.

The now updated HMI and software was then, tested, a new backup taken and delivered to site

Client's Feedback

“We needed advice on what we could do, so Opensoft came out to see us very promptly the next day where they were able to outline the options available to us concisely.

In the end, we opted for a full upgrade, as this was the best solution presented to us.

Many thanks to Opensoft and the team for our new upgrades.

We have already identified further projects for Opensoft to assist with and look forward to our continued partnership.”

Engineering Manager

Ross & Catherall – Doncasters Group

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Dairy Industry – CIP Reporting

Opensoft Systems Ltd — Thu, 08 Jul 2021 15:41:02 +0000

Data Historian & CIP Reporting

Meadow Foods is the UK’s largest independent dairy and a leading supplier of milk and dairy ingredients to the food industry. Their products are categorised into Butters, Creams, Milks, and Cultured & Sweetened products. These are manufactured in three BRC 6, Grade A, accredited factories and packed into a wide variety of pack sizes to suit their customer’s needs. These factories are utilised to supply over 100,000 tonnes of bulk dairy products to their customers.

Click here to visit Meadow Foods website

The Challenge

The processing plant is situated 20 miles South-East of York. It offers around the clock production and manufactures the full range of their sweetened dairy products which are distributed to some of the world’s leading food manufacturers.

In order to cope with around the clock production and to help drive continuous process improvement across their production operations, the company required greater visibility of plant data. Following consultation with Opensoft Systems Ltd, it was agreed to deploy a Data Historian to efficiently collect and store real time data, in order to drive proces
improvements through greater understanding of plant data. The historian allows the business to monitor key metrics relating to process operations throughout the plant.

The Process

Opensoft Systems were chosen to implement the new historian owing to their wealth of experience in integrating automation software across fast-moving process operations. Opensoft recommended a data historian, lending itself well to the real-time process analysis required by the site. The system linked seamlessly to the site’s Kepserver I/O server providing a real-time data stream across the plant’s Mitsubishi Q Series PLCs.

CIP (clean in place) is an important requirement for any food production facility, a change in products manufactured requires a thorough clean of all process equipment prior to re-utilisation for new recipes. Process values such as clean type, temperature, and pressure must be captured by the system for each clean which acts as proof of traceability for end customers and regulatory bodies.

The Result

Following system implementation, training was provided to assist personnel in understanding the configuration of the historian server’s utilities, management of the system, data analysis and production of reports. The software allows for information to be reported in a variety of ways from trends to tabularised data allowing data to be exported to Excel for further analysis.

Historian Trend

Client's Feedback

“Opensoft Systems were chosen to implement the new historian owing to their wealth of experience in integrating automation software across fast-moving process operations.

The system linked seamlessly to the sites Kepserver I/O server providing a real-time data stream across the plants Mitsubishi Q Series PLCs.

‘Meadow Foods’ Group Engineering Manager commented:

We needed a tool that allowed us to understand after-the-event issues across our plant. Opensoft installed the historian with minimal fuss and aligned the reports to our needs very well.”

Engineering Manager

Meadow Foods

Proposed System Architecture

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