The Magical World of Chocolate Manufacture

1. The Magical World of Chocolate Manufacture

2. Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)

3. Introduction Project Solution Agenda Benefits Considerations Summary

4. Chocolate manufacture Pressure and Temperature measurement

5. Project Scope

6. Background to the Project Seamless and transparent integration throughout the Company manufacturing systems and business system Manufacturing system designed for expandability, ease of integration and contextuality. Information that is important, relevant and contextual to be published to a portal for easy access Ability to trend and trace process issues and speed up trouble shooting.

7. Project Goals • Traceability of fat usage and additions against works orders • Monitoring / logging of process parameters • ERP integration to Syspro • Overall system upgraded to latest technologies • Network • Windows / SQL Server environment • SCADA system • PLC system • Ingredient management of recipes • Introduction of expandable reporting infrastructure

8. Introduction Project Solution Agenda Benefits Considerations Summary

9. Tender process Requirements of integrator and solution Cape Town presence Instrumentation, PLC, SCADA and database development experience Previous experience in food and beverage industry Several solutions investigated Siemens Rockwell Citect

10. Why Wonderware Proven functionality in the Food and Beverage industries Proven integration into business systems (SQL database) Well supported, widely used nationally and internationally Several solution providers / system integrators Development into the future Increased availability of resources (call-outs)

12. Project Design Functional specification prepared Detailed design process Network topology PC/Server infrastructure PLC infrastructure Data flow

13. Project Description Develop ArchestrA model S95 standard Model includes future upgrades Use model to define data capturing points for EOM

15. Topology

16. EOM

17. Project Design Design Intouch SCADA Dual display AMR’s first project with ArchestrA 3.0 and Intouch 10.0 Converted AMR’s standard valve/motor SmartSymbols to ArchestrA graphics

18. Project Design

19. Project Description

20. Project Description

21. ERP Integration / WO Management ERP integration to Syspro via holding database WO’s pushed down from Syspro indicating Raw material, tank and equipment allocation/scheduling Operators start and complete WO’s SCADA Intouch SCADA Wonderware Historian Syspro server

22. ERP Integration / WO Management Example of WO Management at SCADA level

23. ERP Integration / WO Management

26. Project Description

27. Project Description

28. WO – Modify execution time

29. WO – Re-allocate

30. WO – Remove from plan

31. PLC Allen-Bradley Compact Logix Beckhoff Ethernet/IP remote I/O units Program designed with complete process control management in mind (for future phases) Manufacturing instructions Process parameters (Mixing times, pressure and temperature checks and operator prompts) Fat transfer route allocation Current program only handles fat transfer route allocation

32. Reporting Wonderware Information Server MS-SQL Reporting services

33. Reporting

34. Reporting

35. Reporting

36. Introduction Project Solution Agenda Benefits Considerations Summary

37. Benefits / Goals Achieved • Batch size consistency • No need for extensive additions to correct recipe failures • Raw material allocations tracked • What fat goes where • Better process control tracking • Alarming at SCADA level • Trouble-shooting (temperatures, pressure, grinding times) • Operators

38. Benefits / Goals Achieved • Significant savings in fat usage • Batch processing times where standardized • Less usage of resources i.e. power • Minimised batch/formulation corrections • Savings in additional raw materials to batches.

39. Introduction Project Solution Agenda Benefits Considerations Summary

40. Lessons Learned (PLC) • User defined data structure always good (duplication of devices similar control) • I/O server integration with tagnames instead of address reference • Ethernet/IP needs managed switches to handle IGMP Snooping (Internet Group Management Protocol)

41. Lessons Learned (Wonderware) Domain Security Tighter control with existing business system and network policies Client responsible for user manager/rights (IT department)

42. Lessons Learned Understanding scope and planning vital Previous projects failures overcome Plant downtime was managed Plant process visibility greatly improved Updated P&ID Operations / process flow Increased speed of data availability

43. Introduction Project Solution Agenda Benefits Considerations Summary

44. Project summary / conclusions Phase I successfully completed by AMR using Wonderware technology Increased process control and shop floor visibility Phase II will further utilize the solution into other areas of the plant Future phases will allow for data to be written back to Syspro Automatically closing works orders

45. Thank you