Client Challenge
A plastics manufacturer sought to modernize their automation system, which was running on an outdated Windows Server 2003 operating system. The legacy system utilized FactoryTalk View Studio 2.2 for operator interfaces and for data trending, and SQL Server for production data logging to a corporate database. The system supported three operator interface PCs in key locations: the main control room, the quality lab, and a remote operator station.
The client’s goals included migrating the FactoryTalk applications to a Windows Server 2016 platform and upgrading operator interface PCs to Windows 10.
The most significant obstacle was migrating FactoryTalk Historian from version 2.2 to 6.1, a rarely attempted upgrade that posed considerable technical challenges.
Our Solution
DSI Innovations devised and executed a comprehensive migration strategy to achieve the client’s modernization objectives. Key steps included:
- Server and Client Upgrades: The FactoryTalk applications were successfully migrated to a Windows Server 2016 R2 platform, and operator interface PCs were upgraded to Windows 10 to improve system performance and security.
- Parallel System Testing: To minimize risk, both the legacy and upgraded systems were operated simultaneously for two weeks. Detailed performance testing confirmed that the new system met or exceeded the reliability and functionality of the old system.
- Data Validation and Transfer: Our team ensured that all archived data from FactoryTalk Historian 2.2 and SQL Server was migrated to the new system. Rigorous data comparisons validated accuracy between the old and new databases.
- Navigating Complex Historian Upgrade: The migration from FactoryTalk Historian 2.2 to 6.1, a complex and rarely attempted procedure, was completed successfully. Drawing on expert collaboration and Rockwell technical support, DSI Innovations overcame significant technical hurdles to deliver a fully functional, upgraded Historian system.
The Results
The modernization effort yielded outstanding results for the client:
- Enhanced System Performance: The updated platform improved operational efficiency, with faster data processing and reduced downtime risks due to outdated software.
- Reliable Data Integrity: All archived data was preserved and seamlessly integrated into the new system, ensuring continuity in production reporting and analytics.
- Validated System Transition: Two weeks of parallel operation provided confidence that the new system functioned at the same or higher standards as the legacy system.
- Successful Historian Upgrade: By completing one of the first migrations from FactoryTalk Historian 2.2 to 6.1 in the region, DSI Innovations delivered a cutting-edge solution for advanced data trending and reporting.
This comprehensive migration positioned the client to leverage modern tools for production monitoring and data analysis, ensuring their automation infrastructure was both future-proof and resilient.
