Global CPG Manufacturer Taps Malisko to Be Master Automation Integrator to Achieve High OEE for New US Production Line
A global consumer products manufacturer made the business case to install a new production / packaging line to increase capacity. The CPG manufacturer wanted the new line to achieve, then maintain, a high Overall Equipment Effectiveness (OEE) to meet production demands. Malisko was asked to be the Lead Automation Integrator for the new line and develop a fully integrated line control with various OEM equipment.
- Achieve a high OEE line performance and optimization to meet aggressive production goals.
- Respond instantly to changes in performance effectiveness
- Connect the controllers of all machines together on a common network to exchange data
- Enable upstream and downstream machine communication.
- Institute a standard inter-processor communications schema and structure for the OEM controls engineers to follow.
- Provide consistency in the data structures and performance-related nomenclature among the OEM controllers for line performance.
- Adhere to the project’s budget and aggressive schedule.
- The “COVID-19 Effect”
- Collaboration had to be mostly “remote”
- Subcontractors from other countries had to hire 2nd and 3rd party resources to communicate and work with Malisko, the client and the other OEMs.
- Multiple language translations
- Communication among international OEMs.
- Tying together different machine types and working with different OEMs
- Very tight schedule required constant coordination with OEMs
- Constantly updating client with status of OEE data implementation.
- Connections to devices that were not natively speaking to each other
- Some machine controllers were not equipped to talk via ethernet
- Weighers and printers not configured for ethernet communications.
- Establish clear and effective communications with the control engineers of each OEM supplier.
- Maintain a regular cadence of meetings among the OEM engineers/programmers.
- Tied together the various OEM controller systems into a “Head PLC” / “Line Control PLC” configuration.
- Enabled machine performance optimization via machine-to-machine communications based on the established standard schema and data structure.
- Made all logical connections to the “Head” ControlLogix.
- Data aggregation of all work cell data to a single point for MES and OEE software platforms.
- Facilitated project and production management alignment and coordination
- Extension of the customer’s project team
- Working with operators, supervisors and leadership
- Expanded project scope during on-site startup and commissioning as requested by the client:
- We weren’t just on the floor programming controllers
- We were coordinating with all the OEMs and filtering their requests to the client
- We served as the primary conduit for communication and coordination
- Extensive on-site testing and information analysis to verify accuracy and reliability of OEE calculations
- Increase efficiency and productivity on the plant floor.
- Project scope, schedule and budget were accomplished.
- Successfully connected all work cells on one line.
- Successfully created dashboards and reported line OEE.
- Client has selected Malisko to expand the implementation to the other lines in the facility.
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