Rock Products

MAR 2013

Rock Products is the aggregates industry's leading source for market analysis and technology solutions, delivering critical content focusing on aggregates-processing equipment; operational efficiencies; management best practices; comprehensive market

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Manufacturing INTELLIGENCE CHALLENGE Optimal control of the manufacturing process. SOLUTION A manufacturing intelligence solution utilizing Kruse Controls��� FactoryTalk system. TIP Dashboards are displayed on LCD screens in break rooms for plant employees. Dry cement may look like a hodge���podge of soot and gravel when it pours out of the bag, but each package is the result of a carefully calculated process. With more than a dozen possible components ��� which can differ based on the aggregate ���recipe��� needed for various construction jobs ��� accuracy and pre��� cision are key to quality control. In addition, the cement manufacturing process must be closely managed to avoid the huge potential for waste as the various ingredients are weighed, heated, combined and packaged. Management at one leading manufacturer of packaged cement realized they lacked the in��� sight needed for optimal control of their man��� ufacturing processes. To identify and correct inefficiencies, the company wanted to shift from manual collection of batch details and bag weights to an automated system that could track this data, and translate the results into meaningful, real���time reports. Managers also wanted the ability to view process graphics beyond the plant floor, and access the systems remotely via a web���inter��� face on a PC or Apple device. The company also wanted a solution that would allow managers to maintain and manage recipes in a secure, central data��� base. In the past, data���entry errors some��� times occurred when operators entered ingredient information into the PLC or HMI on the plant floor. 82 ROCKproducts ��� MARCH 2013 Solutions To achieve these sophisticated manufactur��� ing capabilities, the company turned to Kruse Controls Inc., a control and informa��� tion systems integrator. Kruse Controls ��� a member of the Rockwell Automation Part��� nerNetwork program ��� implemented a man��� ufacturing intelligence solution utilizing the FactoryTalk software suite from Rockwell Automation. First, Kruse Controls updated the informa��� tion architecture to support a thin client en��� vironment. After migrating the existing RSView32 application to FactoryTalk View Site Edition (SE) software, Kruse engineers replaced the PCs on the plant floor ��� which sometimes failed because of the harsh envi��� ronment ��� with ACP���enabled managed thin clients. Kruse Controls deployed FactoryTalk View software from a centralized server that can be accessed via the thin clients in the plant. The software interfaces with ACP ThinMan��� ager, which extends the remote monitoring capability of FactoryTalk View to a PC or Apple device. The new HMI shows the real���time system status in a sophisticated mimic screen and gives operators a detailed overview of each part of the process. With no moving parts, no hard drive and no operating system, the thin clients have excellent reliability. They

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