penn color: leading colorant producer gains access to kaleidoscope of process data

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

http://www.penncolor.com/index.php


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


About Penn Color

Color concentrates and pigment dispersions for

plastics.

Pigment dispersions and functional materials for the

Ink and Coatings Industries.


Business Needs

Quality Analysis

and Improvement

Rapid Product

Development

Efficient Production

Process

Improvement

Preventative

Maintenance


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


Project Team

Work Groups Involved

Internal:

- Quality

- Engineering and Operations

- Information Technology (IT)

Suppliers:

- Rockwell Automation

- Rumsey

Integrator:

EZSoft, Inc

http://www.rockwellautomation.com/index.html



Results:

FactoryTalk VantagePoint portal

enhances trouble shooting capabilities

Methodically streamlines problem-

solving techniques and minimizes

variation

Mitigates user- error variability

Facilitates efficient product output


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


Batch Report Selection


Production Report (Trend/Data)


Production Report (Analysis)


Trend Report


Dashboard


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


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


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


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)


Tank 1 Tank 2

Reactor




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


Tank 1 Tank 2

Reactor




Tank 1 Tank 2

Reactor



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


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


Contact Information

Franc Marmero

Manager of

Manufacturing Automation

Cell Phone: 609-238-9763

Office Phone: 484-568-5040

Email: [email protected]

Al Sylvester

Maintenance Manager

Cell Phone: 267-496-9854

Office Phone: 215-997-2221

Email: [email protected]



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