Client Challenge
A chemical manufacturer wanted to streamline their production process by integrating its control system with its Enterprise Resource Planning (ERP) system. The primary objectives included:
- Automating the flow of recipe information and material consumption between the control system and the ERP.
- Providing operators and employees with remote access to batch and machine data for improved decision-making.
- Ensuring scalability for future facilities and equipment without requiring extensive rework or custom development.
- Achieving a cohesive user experience across multiple locations and equipment setups.
Our Solution
Our team developed a robust and scalable interface between the client’s control system and ERP using a combination of PLC controls, Operator SCADA systems, and Ignition software. Key aspects of the solution included:
- Ignition Architecture:
- We designed a hub-and-spoke Ignition architecture, with Ignition Edge devices running locally on OnLogic IGN-600 Edge Onboard devices.
- The central Ignition hub was configured in the cloud to communicate with the edge devices via a secure gateway network.
- Automated Data Flow:
- We enabled seamless automation of recipe information and material consumption data flow to the ERP.
- Data archiving solutions were developed to ensure all production data was captured and delivered accurately to the ERP system.
- Dynamic Data Visualization:
- Our team built mobile-responsive applications using Ignition Perspective to provide real-time and historical batch data, as well as machine trends, to operators and employees.
- We designed dynamic Perspective screens that adapt to different facilities and equipment, eliminating the need for duplicate custom screens.
- PLC Tag Structures:
- Tag structures were created in the PLCs optimized for Ignition Perspective, supporting the ability to rapidly scale the system across additional equipment and facilities.
- We ensured dynamic functionality so new equipment could be added with minimal changes to the Perspective application.
The Results
The Control System to ERP Interface delivered significant improvements in automation, scalability, and operational efficiency:
- Enhanced Automation: The system eliminated manual data entry, automating recipe and material consumption data flow to the ERP.
- Improved Data Accessibility: Operators and employees now had access to dynamic, mobile-responsive applications for real-time monitoring and historical data analysis.
- Cost-Effective Scalability: The dynamic screen design and tag structures allowed our client to add new equipment and facilities without the need for extensive reconfiguration, reducing costs and time.
- Consistent User Experience: The uniform interface across all facilities and equipment ensured a seamless experience for users.
- Scalable Design: The architecture and design took into account the client’s long-term goals, providing a robust foundation for future expansions.
This project showcased DSI Innovations’ expertise in integrating control systems with business operations, leveraging cutting-edge Ignition technology to deliver scalable, user-friendly, and efficient solutions.
