penn color: leading colorant producer gains access to kaleidoscope of process data
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Penn Color: Leading Colorant Producer Gains
Access to Kaleidoscope of Process Data
Copyright © 2013 EZSoft, Inc. All rights reserved.
Using Manufacturing
Intelligence to
Produce Color for
PLASTICS, INKS, and
COATINGS
Al Sylvester, Penn Color Maintenance Manager
Franc Marmero, EZSoft Manager of Manufacturing Automation
Copyright © 2013 EZSoft, Inc. All rights reserved.
About Penn Color
Penn Color was Founded In 1964
World Leader in Color for Plastics, Inks, and
Coatings
Manufacturing Operations in US, Europe,
and India
Sales Offices in Asia
Copyright © 2013 EZSoft, Inc. All rights reserved.
About Penn Color
Color concentrates and pigment dispersions for
plastics.
Pigment dispersions and functional materials for the
Ink and Coatings Industries.
Copyright © 2013 EZSoft, Inc. All rights reserved.
Business Needs
Quality Analysis
and Improvement
Rapid Product
Development
Efficient Production
Process
Improvement
Preventative
Maintenance
Copyright © 2013 EZSoft, Inc. All rights reserved.
Solution Definition / Evaluation
Definition
Greater Accessibility To Data
Process analysis for continuous improvement
Eliminate Manually Creating Reports
Better Diagnostic Tools
Remote Visibility Of Processes
Infrastructure To Grow The System
Evaluation
Attended Seminars
Spoke With Solution Providers
Attended FactoryTalk®
Historian &
FactoryTalk®
VantagePoint Classes
Copyright © 2013 EZSoft, Inc. All rights reserved.
Project Team
Work Groups Involved
Internal:
- Quality
- Engineering and Operations
- Information Technology (IT)
Suppliers:
- Rockwell Automation
- Rumsey
Integrator:
EZSoft, Inc
Copyright © 2013 EZSoft, Inc. All rights reserved.
Results:
FactoryTalk VantagePoint portal
enhances trouble shooting capabilities
Methodically streamlines problem-
solving techniques and minimizes
variation
Mitigates user- error variability
Facilitates efficient product output
Copyright © 2013 EZSoft, Inc. All rights reserved.
Results Continued:
Instrumental in establishing processing
parameters for new products
Enables set points to maximize output
Enables users to reference accurate
data on a minute by minute basis to
determine product efficiency
Invaluable diagnostic tool
Copyright © 2013 EZSoft, Inc. All rights reserved.
Next Steps: Future Improvements
Develop Plan For Future Deployment And
Changes
Create Install Plan For Production Plants
System Is Scalable
Modeling Data For Global Harmonization
Upgrade some Systems to ControlLogix®
Install Historian Servers at remote facilities and
integrate with FactoryTalk VantagePoint
Copyright © 2013 EZSoft, Inc. All rights reserved.
EZSoft Scope
Documentation
Functional Specification
Factory Acceptance Test (FAT)
Integration
Develop specialized data analysis algorithms
Implement FactoryTalk Historian and
FactoryTalk VantagePoint
Implement FactoryTalk AssetCentre
Reporting
Batch Reports
Trend Reports from Analog Trend Data
Startup / Commissioning
Copyright © 2013 EZSoft, Inc. All rights reserved.
Project Planning
Kick Off Meeting with Quality, Operations and
Engineering and IT
Phase I Pilot
Implement FactoryTalk Historian and one client of
FactoryTalk VantagePoint
Develop Plan / Model For Expansion
Worked closely with Rockwell / Rumsey
Phase II Scalable Architecture
Upgraded to FactoryTalk VantagePoint EMI 4.0
MS SQL 2008
Windows Server 2008
Copyright © 2013 EZSoft, Inc. All rights reserved.
Penn Color – Architecture
Business Network
Existing Control System(s)
FactoryTalk VantagePoint & Historian Server (Physical) • W2K3 Server O/S – Member of Penn Color Domain • Microsoft SQL Server 2005 • Microsoft Office 2007 • FactoryTalk VantagePoint Server • FactoryTalk Historian Site Edition (SE)
Clients (1 Named User)
• XP Pro SP3 & Win 7 Pro
Members of Penn Color Domain
• .NET Framework
• Internet Explorer
• Microsoft Office 2007
Process Network
WAN
Initial Project – Pilot, One Physical Server
QUALITY Allen-Bradley PanelView 1000
Tank 1 Tank 2
Reactor
Tank 1 HighPressure P3Temperature T1Level L2Pressure P4Reactor OK
Tank 1 High (more than 2300mm)
QUALITY Allen-Bradley PanelView 1000
Tank 1 Tank 2
Reactor
Tank 1 HighPressure P3Temperature T1Level L2Pressure P4Reactor OK
Tank 1 High (more than 2300mm)
Copyright © 2013 EZSoft, Inc. All rights reserved.
Virtual Servers
Business Network
Existing Control System(s)
FactoryTalk Historian Server (Physical) • W2K3 Server O/S Member of Penn Color Domain • Microsoft Office 2007 • FactoryTalk Historian Site Edition (SE)
Process Network
WAN
Phase 2 – One Physical Server & Two Virtual Servers
QUALITY Allen-Bradley PanelView 1000
Tank 1 Tank 2
Reactor
Tank 1 HighPressure P3Temperature T1Level L2Pressure P4Reactor OK
Tank 1 High (more than 2300mm)
QUALITY Allen-Bradley PanelView 1000
Tank 1 Tank 2
Reactor
Tank 1 HighPressure P3Temperature T1Level L2Pressure P4Reactor OK
Tank 1 High (more than 2300mm)
FactoryTalk VantagePoint Server • W2K8R2 SP 1 Server O/S Member of Penn Color Domain • Microsoft Office 2010 • FactoryTalk VantagePoint
Clients (3 Named Users
and 3 Concurrent Users)
• XP Pro SP3 & Win 7 Pro
Penn Color Domain
• .NET Framework
• Internet Explorer
• Microsoft Office 2007/2010
FactoryTalk AssetCentre Server • W2K8R2 SP 1 Server O/S Member of Penn Color Domain • Microsoft SQL Server 2008 R2 • FactoryTalk AssetCentre
Penn Color – Architecture
Copyright © 2013 EZSoft, Inc. All rights reserved.
About EZSoft
Systems Integrator – Malvern, PA
Founded 1998
ControlBuilder®
Services
Specification Development
Control Programming
HMI/SCADA Programming
Database Design/Programming
Web-Based Reporting
Manufacturing Execution Systems - MES
Validation – GAMP5
Startup Supervision, Support and Training
Copyright © 2013 EZSoft, Inc. All rights reserved.
Contact Information
Franc Marmero
Manager of
Manufacturing Automation
Cell Phone: 609-238-9763
Office Phone: 484-568-5040
Email: fmarmero@ezsoft-inc.com
Al Sylvester
Maintenance Manager
Cell Phone: 267-496-9854
Office Phone: 215-997-2221
Email: asylvester@penncolor.com
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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