Plant Automation

Case History
Textile Fibers Manufacturing Tracking System

Project
Implemented Manufacturing Execution System to allow tracking of material from startup of production through shipping, and allow operator input of lot information. Captured  operator input in a database for web-based report generation.

Architecture

• Process and packaging line, including spinning, drawing,  drying, cutting, baling, conveying, scales and shipping
  
• Allen Bradley 5/40E PLC with local I/O and multiple remote I/O locations
  
• Two Allen Bradley 2/30 PLCs networked to InTouch HMIs and InTrack clients
  
• Data communications via Ethernet TCP/IP to thirty-eight Wonderware InTouch HMI Operator stations with InTrack  clients and SQL Server Database access
  
• Web-based reporting using Visual Basic and Crystal Reports

Implementation
Our implementation replaced PDP-11/70 with user terminals and an Oracle database for batch tracking and testing. 

It was upgraded to a Windows NT environment running Wonderware InTouch and InTrack on the user terminals, with data logging performed using a Microsoft SQL server database.  The operator interface network communicated to the Allen-Bradley controls through a DataHighway Plus to serial interface and the controls were modified and enhanced to work with the new tracking system.

A series of custom web-based reports using Visual Basic and Crystal Reports 7.0 show sublot information, machine downtimes, shipping status, and availability of inventory.

Status
The plant is running successfully with the new tracking system.  This system is being considered for use as a baseline for other plant sites. 

Following successful startup, ACE was awarded a contract to convert the PLC 2/30 programs to PLC 5Es.