Highlight Reel – Real-time Data And Historical Analytics

IAC’s Automation Support Team (AST) helped a customer succeed by implementing Rockwell Automation FactoryTalk Historian SE and VantagePoint EMI.

The Challenge:

An acrylics manufacturing company struggled to record, gather and store data regarding its products and processes. By manually tracking product information, the company suffered from errors and inaccurate readings. As a result, batches were inconsistent, customers complained and the manufacturer’s bottom line was impacted adversely.

The Goal:

The manufacturer needed a modernized solution with the capabilities to track and archive key performance indicators (KPIs) with each batch of material produced. It needed to be convenient to use, and it needed to provide leadership with the accurate information needed to improve both batch consistency and product quality.

The Success Story:

IAC’s Specialists were called in to help. They supplied a scalable solution that provided reliable real-time and historical data for plant operations along with flexible reporting options for several internal departments. Consequently, operators and engineers were able to drill down into varying KPIs in each individual batch of manufactured acrylic. This automated solution worked harmoniously alongside multiple programmable automation controller platforms and human machine interfaces (HMIs).

The Solution:

Rockwell Automation’s FactoryTalk Historian Site Edition (SE) coupled with Rockwell Automation’s FactoryTalk VantagePoint EMI.

The Tale Of The Tape

FactoryTalk Historian SE allows users to track, trend and archive varying production data points in varying levels of detail and compression. The raw data pulled into Historian is read, analyzed and stored for extended periods of time for retrieval and further analysis, all from one central location in the facility.

FactoryTalk VantagePoint EMI is a web-based reporting solution that “connects” users to the data in a secure and understandable platform. Users can access production information through the VantagePoint EMI portal from just about anywhere. VantagePoint EMI also allows users to generate their own ad hoc reports.

Direct integration with FactoryTalk Alarms and Events allows users of FactoryTalk Historian SE to notify plant operators in real time when one or more KPIs begin to track out of tolerance during production. Analysis of archived information can be used in efforts to increase production while reducing costs.

The Outcome

Getting real-time and historical information to the right people at the right time was the goal of this project, and that’s exactly what the integration of FactoryTalk Historian SE and FactoryTalk VantagePoint EMI did for the customer. This new automation platform allowed the customer to assess collected KPIs and address any problems before product quality was affected.

Data collected from FactoryTalk Historian SE was utilized to create production recipes to further enhance the quality of finished products. As a result, the rate of production increased and overall costs were reduced.

Let IAC’s Specialists study the automation problems in your facility. Together, we can turn your challenges into opportunities and your historical data into fresh, new success stories.

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