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The session will discuss the impact of automating Bonsal American’s data collection efforts at their top 3 packaged concrete production facilities. The primary objectives of the project were to ...

The session will discuss the impact of automating Bonsal American’s data collection efforts at their top 3 packaged concrete production facilities. The primary objectives of the project were to reliably collect and report OEE, bag weights, and additional
process variables for each packaged concrete line, in an effort to replace the manual data collection and performance boards. In addition, a new, more secure and flexible Recipe Management system was requested. Lastly, plant floor PCs were to be replaced with more reliable, and easily replaceable, thin clients. FactoryTalk Metrics is now configured at the top 3 packaged concrete production lines – providing accurate OEE data in real time via the Web browser-based reports. This empowers these facilities to make informed production decisions that focus on the real issues behind inefficiency. In addition, bag weights and dryer process variables are now collected enabling Bonsal to focus on product variance in a meaningful way. The existing recipe management systems at each facility were migrated to a database driven solution that includes a recipe audit trail reducing data entry errors. PanelView™ and RSView®32 applications were migrated to FactoryTalk View SE in a thin-client environment using ACP’s ThinManager, allowing users to remotely shadow the HMIs at each location either passively or interactively based on security level.