As a part of a new aluminum processing plant, TelePro was asked to design, create and install the Level 2 Shop Floor and Scheduling System. We were also asked to help manage process setup and gather quality-related information. The requirements included:
Creating an HMI interface for the process/shop-floor operators
Tracking and storing production scheduling data
Tracking equipment downtime and asset utilization
Creating an interface to share coil process data with another plant
Gathering and storing quality-related data for the process
Gathering and storing detailed data from the process PLCs
Managing and sending preset information to the process PLCs
Shop Floor Automation System Architecture
The Level 2 System consisted of a Dec Alpha System running an Oracle server. This system managed scheduling information, gathered asset utilization and downtime data, stored shop floor related data, sent next coil information to Level 1 and received production summary data from Level 1.
The shop floor HMI was implemented with Citect for Windows (CI Technologies Pty. Ltd.) screens on PCs running in Windows NT 4.0. Screens included scheduling lot operation, coil location tracking, scrap data entry, etc.
A WonderWare InTouch System did process pre-set and quality tracking. Coil scheduling and general process set information was sent to the InTouch System from the Level 2 Alpha. The InTouch System communicated directly with the process PLCs registered to configure pre-set values, as well as gather process quality data during the coil run. After the coil was completed, the InTouch System stored the process summary data to an MS SQL server and sent the data back to Level 2.
Detailed production information was gathered with a WonderWare Industrial SQL System. Process control engineers can later analyze this data.
The systems TelePro put in place are an integral part of this site's manufacturing process. We have met of the main goals for this project, which is to design a system that requires little or no ongoing support and maintenance.