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HydroScada – We Control Water
Date 22.01.12 Category "Divisions, Information Solutions, MES"
What is HydroSCADA™
HydroSCADA is the chosen HMI/SCADA solution for national water management of Israel since 1994
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MES (Manufacturing Execution Systems) Solutions
Contel ITS offers a wide range of Manufacturing Execution Systems (MES) solutions for management of the production floor. To execute projects, we put together a solution that combines software components from the Rockwell Automation‘s Factory Talk Series which we further develop and customize, with libraries and applications built at Contel ITS.
Areas of the proposed solutions:
Production metrics (Overall Equipment Efficiency metrics -OEE)
A manufacturing plant performance monitoring solution for the management echelon enabling a real time response to problems on the production floor. The system enables analyses of plant performance after the fact, using Key Performance Indicators (KPI) and Overall Equipment Efficiency metrics (OEE). The OEE is obtained by collecting the work times planned in the shift schedules, the actual production times on the plant’s production lines, wear and tear and the reasons for it, and the plant’s outputs, and then applying formulas appropriate to the customer. The solution has been implemented at around 100 production lines in Israeli industry, with customers reporting marked improvements and a rapid return on their investment.
Archive of historical production data (Historian)
A solution for mass data collection from the production floor and storage in a database. This component enables data collection at different levels in the production chain, from smart cards on control equipment to plant-wide databases. The solution supports high-speed data collection. See the link to information about the FactoryTalk Historian module from Rockwell Automation.
Conveyance management on the production floor and automated warehouse management solutions
A comprehensive solution for the efficient management of a series of cranes and conveyor belts and control of automated warehouses. This ranges from the supply of software systems for the management and control of sets of cranes and management of conveyance instructions on the production floor, to the supply of comprehensive solutions and setting up of automated warehouses.
Downtime
This solution gathers all the downtime on the production lines and analyzes them using a root cause tree for stoppages at several levels. The system enables Pareto analysis of the reasons for the stoppages, and calculation of the Mean Time Between Failures (MTBF) and the Mean Time To Repair (MTTR).
Human Resources
The solution features the ability to register employees and teams for work cells and shifts according to their skills and qualifications in order to assign them to tasks in work cells in the most effective manner possible.
Technological parameters and quality tests
This solution enables automatic collection of various technical data, such as speed, pressure and temperature from machines with the aid of various sensors, as well as data collection from tests manually initiated by the operators, and checking them against control limits at the level of the production line and the level of the individual item. The solution also enables generation of reports and graphs for process control metrics. Customers who use this essential tool report higher quality production batches and reduced raw material consumption.
Recipe management
A solution offering management of production recipes and tracking of raw materials on the production floor, at various levels. The RSBatch engine can also be incorporated in the solution for batch management in accordance with the S88 standard.
Kit preparation
A solution featuring automated preparation of the manufacturing components required for batch production. The system enables weighing of various components according to production recipes, including the use of online weights and application of control mechanisms for accurate results. The solution is well suited to food, pharmaceutical and paint plants, and to every plant where batch production includes weighing and preparation of material kits for the manufacturing process. For the pharmaceutical industry, Contel uses the DISY module from Rockwell Automation.
Solutions for scheduling work orders on the production floor
A tool for scheduling work orders and production instructions in manufacturing plants. The tool features several levels of scheduling, from a production manager work interface for scheduling and arranging work orders, to finite-capacity scheduling of the production resources according to a complex set of constraints. The solutions include intelligent tools for simulating and predicting production line output in various scenarios. A finite capacity scheduling tool for production resources such as Scheduler from Rockwell Automation can also be incorporated.
Calls
An essential tool for managing maintenance calls in the system for a whole host of issues that occur on the production floor. The tool facilitates links to the e-mail addresses and telephone numbers of the recipients as well as tracking various issues on the production floor, such as suspect products (MRB), maintenance problems, and safety hazards, etc. until they are resolved. The solution incorporates a tool for distributing and issuing messages in the organization for users of the system on the production floor.
Data Transactions (Transaction Manager)
This software component is used to receive control data in the database at set times or according to events on the production floor. The solution uses a standard protocol for communication with the automation layer (OPC), or the Factory Talk Live Data component from Rockwell Automation.
Gateways
Tools used to create interfaces to the various software systems in the plant, such as an ERP system. The solution enables management of interface configurations, interface content, and synchronization between the systems. For interfacing to leading ERP systems, use is made of Rockwell Automation’s FactoryTalk Integrator , which has built-in adapters to them.
Plant Model
The system enables flexible and convenient definition of the plant model by the customer, in accordance with ISA95. For every branch in the plant tree specifying a production hall, department, line, machine or specific assembly, characteristics can be added that define the special behaviors of that branch in the manufacturing process.
Production report tool (Enterprise Manufacturing Intelligence – EMI)
A tool that provides unified access to all manufacturing/plant data sources, and produces web-based reports, such as dashboards and trends. Helps production operators, engineers, supervisors and managers to manage cost, quality, production, assets and resources more effectively, and is implemented with FactoryTalk VantagePoint from Rockwell Automation. Reports can be defined almost immediately and the time-to-value is measured in hours. The product offers exceptional value in terms of access to data.
FactoryTalk Production Center (FTPC) package
An off-the-shelf package for production management from Rockwell Automation, designed for enterprise customers, and which includes application libraries according to specific fields in industry.
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