Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Penn Color: Leading Colorant Producer G...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Using Manufacturing
Intelligence to
Produce Color for
PLASTICS, INKS, a...
Copyright © 2013 EZSoft, Inc. All rights reserved.
About Penn Color
 Penn Color was Founded In 1964
 World Leader in Col...
Copyright © 2013 EZSoft, Inc. All rights reserved.
About Penn Color
 Color concentrates and pigment dispersions for
plast...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Business Needs
 Quality Analysis
and Improvement
 Rapid Product
Devel...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Solution Definition / Evaluation
Definition
 Greater Accessibility To ...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Project Team
Work Groups Involved
 Internal:
- Quality
- Engineering a...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Results:
 FactoryTalk VantagePoint portal
enhances trouble shooting ca...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Results Continued:
 Instrumental in establishing processing
parameters...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Batch Report Selection
Copyright © 2013 EZSoft, Inc. All rights reserved.
Production Report (Trend/Data)
Copyright © 2013 EZSoft, Inc. All rights reserved.
Production Report (Analysis)
Copyright © 2013 EZSoft, Inc. All rights reserved.
Trend Report
Copyright © 2013 EZSoft, Inc. All rights reserved.
Dashboard
Copyright © 2013 EZSoft, Inc. All rights reserved.
Dashboard
Copyright © 2013 EZSoft, Inc. All rights reserved.
Next Steps: Future Improvements
 Develop Plan For Future Deployment An...
Copyright © 2013 EZSoft, Inc. All rights reserved.
EZSoft Scope
 Documentation
 Functional Specification
 Factory Accep...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Project Planning
 Kick Off Meeting with Quality, Operations and
Engine...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Penn Color – Architecture
Business Network
Existing Control System(s)
F...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Virtual Servers
Business Network
Existing Control System(s)
FactoryTalk...
Copyright © 2013 EZSoft, Inc. All rights reserved.
About EZSoft
 Systems Integrator – Malvern, PA
 Founded 1998
 Contro...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Contact Information
Franc Marmero
Manager of
Manufacturing Automation
C...
Copyright © 2013 EZSoft, Inc. All rights reserved.
Questions?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
www.rsteched.com
Follow RSTechED on Facebook & Twitter.
Co...
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Penn Color: Leading Colorant Producer Gains Access to Kaleidoscope of Process Data

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Penn Color implemented a production intelligence strategy using FactoryTalk Historian, VantagePoint, and AssetCentre to increase visibility into their process and decrease troubleshooting time. While routine maintenance issues could previously take days to remedy, the company now resolves issues at multiple plants from a centralized location within minutes. Pulling data from 1,300 collection points, the new system gives operators insight into processes to make better, faster decisions. They also eliminated paper reporting and now provide customers with product quality reports – a valuable bonus.

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Penn Color: Leading Colorant Producer Gains Access to Kaleidoscope of Process Data

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Penn Color: Leading Colorant Producer Gains Access to Kaleidoscope of Process Data
  2. 2. Copyright © 2013 EZSoft, Inc. All rights reserved. Using Manufacturing Intelligence to Produce Color for PLASTICS, INKS, and COATINGS Al Sylvester, Penn Color Maintenance Manager Franc Marmero, EZSoft Manager of Manufacturing Automation
  3. 3. Copyright © 2013 EZSoft, Inc. All rights reserved. About Penn Color  Penn Color was Founded In 1964  World Leader in Color for Plastics, Inks, and Coatings  Manufacturing Operations in US, Europe, and India  Sales Offices in Asia
  4. 4. Copyright © 2013 EZSoft, Inc. All rights reserved. About Penn Color  Color concentrates and pigment dispersions for plastics.  Pigment dispersions and functional materials for the Ink and Coatings Industries.
  5. 5. Copyright © 2013 EZSoft, Inc. All rights reserved. Business Needs  Quality Analysis and Improvement  Rapid Product Development  Efficient Production  Process Improvement  Preventative Maintenance
  6. 6. Copyright © 2013 EZSoft, Inc. All rights reserved. Solution Definition / Evaluation Definition  Greater Accessibility To Data  Process analysis for continuous improvement  Eliminate Manually Creating Reports  Better Diagnostic Tools  Remote Visibility Of Processes  Infrastructure To Grow The System Evaluation  Attended Seminars  Spoke With Solution Providers  Attended FactoryTalk ® Historian & FactoryTalk ® VantagePoint Classes
  7. 7. Copyright © 2013 EZSoft, Inc. All rights reserved. Project Team Work Groups Involved  Internal: - Quality - Engineering and Operations - Information Technology (IT) Suppliers: - Rockwell Automation - Rumsey Integrator: EZSoft, Inc
  8. 8. Copyright © 2013 EZSoft, Inc. All rights reserved. Results:  FactoryTalk VantagePoint portal enhances trouble shooting capabilities  Methodically streamlines problem- solving techniques and minimizes variation  Mitigates user- error variability  Facilitates efficient product output
  9. 9. Copyright © 2013 EZSoft, Inc. All rights reserved. Results Continued:  Instrumental in establishing processing parameters for new products  Enables set points to maximize output  Enables users to reference accurate data on a minute by minute basis to determine product efficiency  Invaluable diagnostic tool
  10. 10. Copyright © 2013 EZSoft, Inc. All rights reserved. Batch Report Selection
  11. 11. Copyright © 2013 EZSoft, Inc. All rights reserved. Production Report (Trend/Data)
  12. 12. Copyright © 2013 EZSoft, Inc. All rights reserved. Production Report (Analysis)
  13. 13. Copyright © 2013 EZSoft, Inc. All rights reserved. Trend Report
  14. 14. Copyright © 2013 EZSoft, Inc. All rights reserved. Dashboard
  15. 15. Copyright © 2013 EZSoft, Inc. All rights reserved. Dashboard
  16. 16. Copyright © 2013 EZSoft, Inc. All rights reserved. Next Steps: Future Improvements  Develop Plan For Future Deployment And Changes  Create Install Plan For Production Plants  System Is Scalable  Modeling Data For Global Harmonization  Upgrade some Systems to ControlLogix ®  Install Historian Servers at remote facilities and integrate with FactoryTalk VantagePoint
  17. 17. Copyright © 2013 EZSoft, Inc. All rights reserved. EZSoft Scope  Documentation  Functional Specification  Factory Acceptance Test (FAT)  Integration  Develop specialized data analysis algorithms  Implement FactoryTalk Historian and FactoryTalk VantagePoint  Implement FactoryTalk AssetCentre  Reporting  Batch Reports  Trend Reports from Analog Trend Data  Startup / Commissioning
  18. 18. Copyright © 2013 EZSoft, Inc. All rights reserved. Project Planning  Kick Off Meeting with Quality, Operations and Engineering and IT  Phase I Pilot  Implement FactoryTalk Historian and one client of FactoryTalk VantagePoint  Develop Plan / Model For Expansion  Worked closely with Rockwell / Rumsey  Phase II Scalable Architecture  Upgraded to FactoryTalk VantagePoint EMI 4.0  MS SQL 2008  Windows Server 2008
  19. 19. Copyright © 2013 EZSoft, Inc. All rights reserved. Penn Color – Architecture Business Network Existing Control System(s) FactoryTalk VantagePoint & Historian Server (Physical) • W2K3 Server O/S – Member of Penn Color Domain • Microsoft SQL Server 2005 • Microsoft Office 2007 • FactoryTalk VantagePoint Server • FactoryTalk Historian Site Edition (SE) Clients (1 Named User) • XP Pro SP3 & Win 7 Pro Members of Penn Color Domain • .NET Framework • Internet Explorer • Microsoft Office 2007 Process Network WAN Initial Project – Pilot, One Physical Server QUALITY Allen-Bradley PanelView 1000 Tank 1 Tank 2 Reactor Tank 1 High Pressure P3 Temperature T1 Level L2 Pressure P4 Reactor OK Tank 1 High (more than 2300mm) QUALITY Allen-Bradley PanelView 1000 Tank 1 Tank 2 Reactor Tank 1 High Pressure P3 Temperature T1 Level L2 Pressure P4 Reactor OK Tank 1 High (more than 2300mm)
  20. 20. Copyright © 2013 EZSoft, Inc. All rights reserved. Virtual Servers Business Network Existing Control System(s) FactoryTalk Historian Server (Physical) • W2K3 Server O/S Member of Penn Color Domain • Microsoft Office 2007 • FactoryTalk Historian Site Edition (SE) Process Network WAN Phase 2 – One Physical Server & Two Virtual Servers QUALITY Allen-Bradley PanelView 1000 Tank 1 Tank 2 Reactor Tank 1 High Pressure P3 Temperature T1 Level L2 Pressure P4 Reactor OK Tank 1 High (more than 2300mm) QUALITY Allen-Bradley PanelView 1000 Tank 1 Tank 2 Reactor Tank 1 High Pressure P3 Temperature T1 Level L2 Pressure P4 Reactor OK Tank 1 High (more than 2300mm) FactoryTalk VantagePoint Server • W2K8R2 SP 1 Server O/S Member of Penn Color Domain • Microsoft Office 2010 • FactoryTalk VantagePoint Clients (3 Named Users and 3 Concurrent Users) • XP Pro SP3 & Win 7 Pro Penn Color Domain • .NET Framework • Internet Explorer • Microsoft Office 2007/2010 FactoryTalk AssetCentre Server • W2K8R2 SP 1 Server O/S Member of Penn Color Domain • Microsoft SQL Server 2008 R2 • FactoryTalk AssetCentre Penn Color – Architecture
  21. 21. Copyright © 2013 EZSoft, Inc. All rights reserved. About EZSoft  Systems Integrator – Malvern, PA  Founded 1998  ControlBuilder®  Services  Specification Development  Control Programming  HMI/SCADA Programming  Database Design/Programming  Web-Based Reporting  Manufacturing Execution Systems - MES  Validation – GAMP5  Startup Supervision, Support and Training
  22. 22. Copyright © 2013 EZSoft, Inc. All rights reserved. Contact Information Franc Marmero Manager of Manufacturing Automation Cell Phone: 609-238-9763 Office Phone: 484-568-5040 Email: fmarmero@ezsoft-inc.com Al Sylvester Maintenance Manager Cell Phone: 267-496-9854 Office Phone: 215-997-2221 Email: asylvester@penncolor.com
  23. 23. Copyright © 2013 EZSoft, Inc. All rights reserved. Questions?
  24. 24. 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 24 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  25. 25. 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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