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5 case studies
Process Control System Support
AUVESY-MDT
In many automated production facilities, changes are made to SIMATIC PCS 7 projects on a daily basis, with individual processes often optimised by multiple workers due to shift changes. Documentation is key here, as this keeps workers informed about why a change was made. Furthermore, SIMATIC PCS 7 installations are generally used in locations where documentation is required for audits and certification. The ability to track changes between two software projects is not only an invaluable aid during shift changes, but also when searching for errors or optimising a PCS 7 installation. Every change made to the system is labour-intensive and time-consuming. Moreover, there is also the risk that errors may occur. If a change is saved in the project, then the old version is lost unless a backup copy was created in advance. If no backup was created, it will no longer be possible to return to the previous state if and when programming errors occur. Each backup denotes a version used by the SIMATIC PCS 7 system to operate an installation. To correctly interpret a version, information is required on WHO changed WHAT, WHERE, WHEN and WHY: - Who created the version/who is responsible for the version? - Who released the version? - What was changed in the version i.e. in which block or module of the SIMATIC PCS 7 installation were the changes made? - When was the version created? Is this the latest version or is there a more recent version? - Why were the changes made to the version? If they are part of a regular maintenance cycle, then is the aim to fix an error or to improve production processes? - Is this particular version also the version currently being used in production? The fact that SIMATIC PCS 7 projects use extremely large quantities of data complicates the situation even further, and it can take a long time to load and save information as a result. Without a sustainable strategy for operating a SIMATIC PCS 7 installation, searching for the right software version can become extremely time-consuming and the installation may run inefficiently as a result.
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Versiondog Comes for Coffee
AUVESY-MDT
“Well before it went live, we had worked out a clear plan for exactly how we were going to use the new versiondog versioning and data management software from AUVESY,” says Michael Mrugalla, who works in process automation at the Mainz plant. “We also had to think about what backups really meant for us. With all our field devices, control programs, drive systems, programming languages, file formats and software applications, we needed to know precisely what we have to back up in case a breakdown (e.g. a power outage) stops production. Because the whole point of making a backup is to be able to recover data quickly and easily when something goes wrong and continue working as if nothing had happened. But that means more than simply restarting production, it also means we need to be able to pick up where we left off with our ongoing process maintenance and optimisation.” It was particularly important to Nestlé that their backup strategy be built around a sin-gle continually active and universally appli-cable solution. And they wanted it to maintain a centralised backup of all the data necessary for both recovery and further development for all devices and all related projects (i.e. every piece of hardware and software). And the programs actually running on controllers need to correspond precisely with the data on the server. If not, the reason must be easily identifiable and the valid version always available to be reloaded onto the device.
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Maintenance efficiency – automated
AUVESY-MDT
Egger Ltd at Hexham, Northumberland, UK, manufactures chip board and associated products on highly automated production lines. The programs within numerous manufacturing systems and controllers are vital to the resulting OEE of the company and require frequent back up, version control and automatic administration. Egger standardised on Versiondog software from SolutionsPT to undertake and manage this task.
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Refreshingly efficient
AUVESY-MDT
Data management system versiondog, an indispensable instrument in operations engineering at Warsteiner. Preventive maintenance has long been the norm at the Warsteiner Brewery. And yet, unplanned maintenance activity can still occur. It is therefore of great importance that the latest update version for each and every PLC be stored centrally. In this industry, there is no time to waste trying to conduct a search.
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Crossing the Atlantic to Argentina
AUVESY-MDT
Between 2005 and 2010, Aluar went through a substantial growth phase where most of the production facilities were upgraded. As a result of this expansion, the number of PLCs increased from 100 to 300. When it came to managing the control program software, however, flaws and cracks began to show in the established workflow and version control procedures that had prior to the growth phase, been based on manual backups and documentation. A rapid growth in the number of automation and maintenance staff (>100 users) also coincided with increasing accounts of infrequent and incomplete documentation of software versions, which then required an increasing effort where bug tracing and detection were concerned. This increased the risk of incidents that could not only affect operation, but that could also result in stoppages at the mid-term. It also increased the risk of safety risks remaining undetected.
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