Project Drive

A leading manufacturer of high-quality, single-source recipe pet food with facilities across North America required a production scheduling management and OEE tracking system for a greenfield Facility. Ignition by Inductive Automation along with the OEE and Scheduling module from Sepasoft was chosen for the SCADA and MES platform, and the required functionality was developed by Corso Systems and tested with various OEM manufacturers on the various production and packaging lines at the facility.

Solution

Corso Systems worked with the OEM equipment manufacturers on the production and packaging lines to implement an OEE tracking and production scheduling system at a greenfield pet food facility in Canada.

Corso Systems developed the Ignition architecture and screens to manage work orders, production scheduling, OEE tracking and dashboards, as well as an advanced reporting system. This included developing the production model for the Sepasoft OEE and Scheduling Module to assign work orders to production and packaging lines, start and stop production runs, and manage work order quantities. As work orders reached their desired quantities production runs were stopped automatically.

As new recipes were added to the ERP system for new products, a script was developed by Corso to automatically generate the required materials for the production scheduling functionality, including selecting on which lines materials were allowed to be run. Scheduling was managed with the drag and drop interface built-in to the Sepasoft modules, and the schedule was managed with the Schedule View Component.

This system was designed and developed during the construction of the facility, allowing production data including OEE to be collected during testing of equipment, and put into production with the first production runs on the line.

Benefits

• The control system was fully-integrated into the company's ERP system enabling real-time scheduling and inventory management.

• OEE Data was tracked starting from the first production order through the system

• Automatic work order management from the ERP system allowing orders to be scheduled the moment they are entered in the ERP system

• Reporting and analytics providing the capability for maintenance to prioritize work on the system to increase throughput and reduce downtime

• Real-time dashboards for plant-floor OEE display

Project Details

Industry Pet Food

Location Alberta Canada

Services SCADA, MES, OEE and Downtime Tracking, Production Scheduling, Database Management, Process Analytics, Process Optimization

Technology

• Inductive Automation’s Ignition

• Sepasoft OEE and Scheduling Module

• SQL Server

• Infor M3 ERP

Focus

• Implement production scheduling and automated work order management

• Track OEE for the facility starting with the first production runs

• Advanced Process Analytics and reporting