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AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
AP17: Saint-Gobain Builds for the Future  with PlantPAx and Production Intelligence
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AP17: Saint-Gobain Builds for the Future with PlantPAx and Production Intelligence

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The production systems at a key Saint-Gobain facility, where high-tech fiber glass and construction materials are created, was at risk of obsolescence. With limited support and system expertise, …

The production systems at a key Saint-Gobain facility, where high-tech fiber glass and construction materials are created, was at risk of obsolescence. With limited support and system expertise, maintenance and repairs were hard to sustain on the legacy process system. To remain competitive, the company turned to the PlantPAx process system with a production intelligence solution for increased productivity and reduced downtime. Utilizing FactoryTalk VantagePoint, View and Historian, the company now has access to a wealth of data for real-time trending and improved electronic data storage from three months to a year.

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  • 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Saint-Gobain Builds for the Future with PlantPAx and Production Intelligence Nick Thompson – Plant Superintendent Larry Grate – Account Delivery Manager
  • 2. AGENDA  Who is Saint-Gobain and PREMIER  Business Justification  Migration Strategy to PlantPAx TM  Leverage Production Intelligence  Solution  Results and Look Forward  Questions and Answers
  • 3. WHO IS ADFORS SAINT-GOBAIN? Nick Thompson Plant Superintendent
  • 4. ADFORS OVERVIEW  Saint-Gobain, the World Leader in sustainable habitat and construction markets, designs, manufactures and distributes BUILDING AND HIGH-PERFORMANCE MATERIALS, providing innovative solutions to the challenges of growth, energy efficiency, and environmental protection.  Saint-Gobain manufactures the following materials:  Flat Glass  Ceramic Materials  Abrasives  Performance Plastics  Saint-Gobain ADFORS  Exterior Wall Insulation (VERTEX)  Wall Coverings (NOVELIO)  Joint Tape (FibaTape)  Bonded glass for thermal insulation and asphalt toppings (NewYorkWire,GlasGrid).
  • 5. WHO IS PREMIER? Larry Grate Account Delivery Manager
  • 6. PREMIER OVERVIEW For more info . . . Visit PREMIER’s website at www.premier-system.com  Founded in 1991  Privately Owned  100+ Employees  CSIA Certified (6 Years)  Corporate Office Located in Smyrna, TN  Regional Operations in S.E. U.S.  Smyrna,TN  Decatur, AL  Cincinnati, OH
  • 7. PREMIER OVERVIEW  Rockwell Solution Partner  Rockwell Control Solution Partner  Rockwell Information Solution Partner  Rockwell Process Solution Partner  Competencies  PLC/DCS Programming and Configuration  HMI Development  MES Solutions  Legacy PLC/DCS Retrofits  Coordinated Drives Solutions For more info . . . Visit PREMIER’s website at www.premier-system.com Information
  • 8. PREMIER OVERVIEW  Industries  Automotive  Chemical  Consumer Products  Food & Beverage  Metals  Pulp & Paper  Power For more info . . . Visit PREMIER’s website at www.premier-system.com
  • 9. BUSINESS JUSTIFICATION  Lost our internal ProcessLogixTM Champion  Support for the Existing Solution increasingly difficult to find.  Have a small PlantPAx system in place for Resin Blending.  This in conjunction with ProcessLogix being based on 1756 I/O made the best solution easy to choose.  Had experienced the advantages of built in directed diagnostics.  Liked the ability to find trained resources on Rockwell solutions.  ProcessLogix Server stability was becoming a problem.  Unsupported Platform from Rockwell  Unsupported Hardware/Software (Windows 2000)
  • 10. BUSINESS JUSTIFICATION  Project justification was on Cost Avoidance.  If a failure occurred the MTTR would be significant, increasing production costs.  On power outages we were having a difficult time recovering due to issues with the ProcessLogix servers.  When process improvements were implemented the labor cost for ProcessLogix integration would be higher than PlantPAx.
  • 11. MIGRATION STRATEGY  Had existing solution in place for Resin, wanted to build on it.  Had an infrastructure that was expanded multiple times without a well thought out strategy.  Had legacy code that needed to be cleaned up.  Needed to install the upgrade on a short outage.  Operators were already familiar with the Resin system faceplates and control.
  • 12. EXISTING INFRASTRUCTURE
  • 13. FINAL INFRASTRUCTURE
  • 14. LEGACY CODE MIGRATION  Integrator documented all existing loops.  Reviewed code list with production for equipment that was out of service or provided poor performance.  Converted existing code and tuning values.  Some sequences were eliminated due to better tools in PlantPAx.  Consolidated multiple HMI platforms from other systems into the new FactoryTalk® View SE system.  Pulper RSView32 System.  Line Drive RSView32 System.  Multiple PV+ Applications.
  • 15. NEEDED TO INSTALL ON A SHORT OUTAGE  Initially targeted a 24 hour production down.  Integrator put together a thorough test plan for critical loops at startup.  Actual outage was 36 hours due to other maintenance.  Startup went extremely well.  We did have a path back to the ProcessLogix system if we had a catastrophic problem.  We moved two ControlNet Racks to Ethernet due to failing control net cables installed crossing the machine in the basement.  We did have access to the ProcessLogix code if needed to verify operation.
  • 16. OPERATOR FAMILIARITY  Operators were already comfortable with the HMI due to the existing Resin PlantPAx implementation.  Operator training on the HMI was minimal, screens mimicked the existing ProcessLogix using familiar faceplates.
  • 17. OPERATOR FAMILIARITY
  • 18. OPERATOR FAMILIARITY
  • 19. LEVERAGING PRODUCTION INTELLIGENCE  Chose to use FactoryTalk Historian as a replacement for the ProcessLogix Historian.  Chose to use FactoryTalkVantagePoint to provide production intelligence to operations management.  Chose to use FactoryTalk AssetCentre for Disaster recovery and backup.  Chose to use ACPThin Manager for HMI clients and engineering station.
  • 20. LEVERAGING FACTORY TALK HISTORIAN
  • 21.  Used to create trends relating critical process values for a quick overview of production quality.  Used to create ad hock reporting to troubleshoot process problems as they arise.  Used to create required environmental reporting.  Working on Production dashboards for critical KPI’s.
  • 22. THICK STOCKVS LEVEL
  • 23. AD HOCK
  • 24. ENVIRONMENTAL REPORTING
  • 25.  Repository for plant wide control asset programs.  Automated disaster recovery on critical process assets.
  • 26. FactoryTalk AssetCentre DIRECTORY
  • 27. FactoryTalk AssetCentre AUDIT LOGS
  • 28. THIN MANAGER  Tool for managing HMI’s across the facility.  Provides for remote shadowing of operator screens for troubleshooting and diagnostics.  Makes terminal replacement simple.  Simplifies the use ofTerminal Services for FactoryTalkView HMI servers.
  • 29. THIN MANAGER TREE
  • 30. THIN MANAGER SHADOW
  • 31. SOLUTION  Live Demo of Graphics
  • 32. MAIN OVERVIEW
  • 33. LINE DRIVES CONVERTED PV DISPLAY
  • 34. DIAGNOSTIC EXAMPLES
  • 35. RESULTS/PATH FORWARD  KPI Screens in FactoryTalkVantagePoint  Converting balance of plant to Ethernet  Automated Reporting of Production  Additional Process Improvements
  • 36. ANY QUESTIONS? Please email us for additional information. nick.thompson@saint-gobain.com or larry.grate@premier-system.com
  • 37. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 37 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  • 38. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you for attending our session!

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