Client Challenge
A forest product manufacturer faced significant inefficiencies in managing their automation system due to a fragmented approach to PLC and HMI program storage, firmware inconsistencies across various processors, and decentralized Rockwell activation license management.
These issues resulted in frequent machine downtimes, difficulty in maintaining program version control, and escalating costs tied to redundant license usage. The absence of a centralized disaster recovery plan further compounded the risks, leaving the manufacturer vulnerable to extended operational interruptions.
Our Solution
- Our team addressed the client’s challenges by implementing a robust, centralized system for managing plant automation programs and licenses.
- A central server was established to consolidate all PLC and HMI program files, ensuring Real-Time Access and consistent version control across the plant.
- To safeguard against data loss and unauthorized edits, automatic backup schedules were introduced, providing Real-time change monitoring and comprehensive disaster recovery capabilities.
- In order to optimize Rockwell activation license management, all licenses were centralized, enabling better oversight and eliminating the inefficiencies caused by decentralized usage. An outdated server was repurposed into a remotely accessible engineering workstation, granting secure, individual user access to essential tools and programs. Field laptops were also integrated into the centralized system, allowing technicians to seamlessly connect and manage standalone PLCs in remote areas.
The Results
The implementation of a centralized system delivered transformative results for the forest product manufacturer. Key outcomes included:
- Elimination of rogue PLC program copies: By consolidating program storage, the client gained full control over their automation assets, preventing unauthorized edits and ensuring consistency.
- Improved disaster recovery: The automated backup system enabled rapid identification of program changes and swift restoration in the event of machine failure, minimizing downtime.
- Cost savings: Centralized license management reduced redundant license expenses and optimized usage across the plant.
- Enhanced operational efficiency: The new remote engineering workstation and field laptop integration streamlined access for technicians, improving response times and system reliability.
Overall, the centralized approach provided the manufacturer with a more reliable, efficient, and cost-effective way to manage their automation system, empowering them to focus on production goals with confidence.
