Our Logic Sequence Manager Can’t Handle The Number Of Steps Our Process Entails. What’s The Best Way To Integrate FT Batch?
What Our Client Said
We know LSI because you helped us to put our fabric softener perfume pellet factory together a few years ago. You understand our technology and our processes. Now we need to do concurrent feeds, and we need to replace our existing custom Logic Sequence Manager with FactoryTalk (FT) Batch.
What We Heard
FT Batch will make our systems much easier to run and modify, but we need help integrating it. Not only do we need help today, we need this change to reduce future development costs. We need the flexibility of FT Batch so that it can be accessed easily in the future by any MES system.
What We Did
Working within a system that included a ControlLogix controller 1756- L74, Remote IO (consisting of 1756 IO, 1794 Flex IO and 1734 Point IO communicating via ethernet), METTLER TOLEDO’s IND780 (to manage the feeds), server computers running Wonderware’s System Platform, DA Servers, and Historian and desktop computers running the InTouch HMI and Trending client, LSI updated the PLC programs as well as the dosing phases. We also updated the related HMI screens and Wonderware System Platform objects. Finally, we helped to construct the customer’s recipes through the FT Batch Equipment Editor and Recipe Editor. Concurrent feeds aren’t just possible, they’re simple.
- Updates to PLC programs as well as the dosing phases
- Updates to the related HMI screens and Wonderware System Platform objects
- Help in developing the related recipes through FT Batch’s “Equipment Editor” and “Recipe Editor”
The Results Speak For Themselves
Throughput improved by 15%
Integrating FT Batch was a game changer. Not only could recipes be updated and implemented faster, the new system’s positive impact could be felt throughout the manufacturing process. In the end, the customer was able to get significantly more done without a significant upgrade in hardware.
Easier formulation changes
The customer needed more flexibility to adapt to changes with their manufacturing process, and LSI’s implementation of FT Batch accomplished that. Everything from a small recipe tweak to a complete reformulation can now be accomplished with little disruption to the overall process.
Reduced future development costs
Now that the customer’s process includes FT Batch, the opportunities to expand their systems are plentiful. Best of all, this expansion is more cost effective thanks to the expandability of FT Batch as implemented by LSI.
LSI listened, then identified the best way to integrate FT Batch into the customer’s current manufacturing process. We implemented a futureready system that lets the customer perform concurrent feeds, and the resulting improvements in productivity have been dramatic.
The customer needed to be able to run concurrent feeds and LSI delivered. By integrating FT Batch into their system, throughput was improved by 15% and future expandability was assured without significant changes to existing infrastructure.
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