AP14 - Land O'Lakes Modernization Increases Batch Througput ROKTechED 2016

Land O'Lakes
Modernization Increases Batch Throughput, Cuts Days of Downtime
PUBLIC
Rockwell Automation TechED 2016
@ROKTechED
#ROKTechED
Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.
Speakers
Esden Schreier
Maintenance Manager
Land OLakes
Tim Barthel
Design Engineering Manager
Cybertrol Engineering
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Agenda
Introductions/Company Overviews
Business Challenges
Path to Success
Benefits
Next steps
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Agenda
Business Challenges
Solutions
Benefits
Next steps
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Land O Lakes dairy co-op

We are broken into different divisions
Dairy Foods
Crop Inputs
Feed
Dairy foods division comprised of 11 facilities

Pine Island facility Specializes in the production
of cheese powder
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Cybertrol Engineering Overview

Control and Information Systems Integrator
Rockwell Automation Solution Partner (Control/Process/Information)
Thousands of projects for over 400 clients
@CybertrolEng
cybertrol-engineering
Excellence
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Integrity
Achievement
Agenda
Business Challenges
Path to Success
Benefits
Next steps
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Business Challenge
Reasons for upgrading
2009
Legacy PLC and HMI System unsupported infrastructure
Old PC based system on Windows 2000
Batching system that was proprietary and unsupported by the developer
Linear batching system hand entered values
each ingredient had to wait for the previous one
to finish
Time consuming and most items manually bypassed
No visibility into the operation no data collection
available
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Business Challenge
Reasons for continued upgrades
2014
Physical server systems Slow, outdated, unsupported
Operating systems Windows 2003/Windows XP
Software versions Not kept up to date with technology
advancements
Increased need for external visibility
Process and Energy optimization for increased savings
System monitoring to reduce downtime with the use of
data collection
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Agenda
Business Challenges
Path to Success
Benefits
Next steps
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10
Path to Success
History of the upgrade
2009
2014
Upgrade to the FactoryTalk

and ControlLogix Platform
PLC to ControlLogix
Batching System
HMI and Information system
Reporting Interface
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Server upgrade physical to

virtual
SAN Infrastructure
Software and Operating System
Upgrade
Visibility and support additions
11
Business Challenge - 2009

Obsolete Equipment
Process Control Hardware Legacy system

Failures were common
PLC code was undocumented
DOS based programming
Support was lacking
Higher cost of ownership spare parts, lack of
standardization
PC operating systems needed updating

HMI was per PC one change required updating all
PCs
No shared resources for screen
No system redundancy
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12
Solution
Upgrade to Rockwell Automation
Out with the OLD
In with the NEW
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13
Solution
Upgrade to Rockwell Automation
PLC Upgrade Migration to ControlLogix
HMI Redundancy Server Client system

Batching Process S88 solution
Historical Data Logging and Archiving

Reporting Trends and Dashboards
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14
Batching system proprietary system
System operated on clipboards

Manual batch ingredient entry by operator
Source code not available for edit

Inefficient method of recipe
editing/loading by operations
Linear operation each ingredient added
one at a time
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15
Solution
FactoryTalk Batch with Web Interface
R/D: Corporate Recipes
Recipe Edit
Recipe List
Excel/Word
Structure in
Specified Format
Information for Stakeholders
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Onsite Production Scheduling
Process Batch
Control System
Plant Floor
16
Solution
FactoryTalk Batch with Web Interface
Parallel vs Serial
operation
User friendly operation screens with

batch interface
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17

Cleaning Efficiencies
Clean-in-place (CIP) Scheduling
Sequence of cleaning not optimized
easily required PLC changes
Interlocking between process and CIP
No visibility of sequencing and pulsing
for sanitation manager
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18
Solution
Recipe Based CIP System
Process and Cleaning operation controlled through
FactoryTalk Batch
CIP Steps easy to view by sanitation manager
Sequence of operation changes simplified with
function block
Interlocking performed at the server level to ensure
production and CIP separation
Viewable within BatchView for status
FactoryTalk VantagePoint CIP Reports showing
real time plus event based data
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19

Staying Current
Servers physical hardware end of life
PCs on plant floor for HMI operation
Applications combined in fewer workloads
Visibility limited
High cost of maintenance
Application and Operating system versions
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20
Solution
Virtualization
VMware Virtual Server Infrastructure
High Availability/Fault Tolerance
Shared Storage and Scheduled Backups
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21
Solution
Virtualization
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22
Agenda
Business Challenges
Path to Success
Benefits
Next steps
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23
Business Benefits
Visibility and Data Analysis
View of operation by maintenance
Tablet usage on the plant floor
Energy data collection
Process optimization
Remote support offsite
Troubleshooting find problems
before they happen
Emailed Warning and Alerts
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24
Benefits
Plant Savings
Migration to batch with scheduling
application view from office what is
currently running
Batch time reduction of 10 mins per batch
Able to increase batch sizes
Operational efficiencies with the
FactoryTalk View SE system
6% Increase in production over two years
Allows for increase in capacity for
entire division
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25
Benefits
Production and Energy Visibility
Visibility utilizing FactoryTalk VantagePoint
Daily Plant Production updates
Energy Usage
Batch and Cleaning Reports
Efficiency reports
Visibility of Plant Operation using
ThinManager
Shadowing Sessions
Remote Clients
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26
Benefits
Shift Reports
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27
Benefits
Shift Reports
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28
Benefits
Plant Savings
Real time information for real time decisions
Maintenance cost reduction on equipment
spending for repairs
Downtime reduction just in automation
2013 - 49.38 Hours
2015 14.5 Hours
Downtime reduction allowed maintenance to focus
on the true asset reliability 11 days of production
back to the facility over 2 years
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29
Agenda
Business Challenges
Path to Success
Benefits
Next steps
@ROKTechED
#ROKTechED
30
Next Steps
Continued Growth in Visibility
Troubleshooting using FactoryTalk VantagePoint process or other
troubleshooting by making an ad-hoc trend
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31
Next Steps
Energy Savings
Energy analysis collection and reporting on energy usage will allow for future
plant savings
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32
Next Steps
Support
Software Support monthly report on system health keep the system running
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33
Next Steps
Continued Improvements
Information allows for analysis and priority of repairs
Remaining legacy IO can be replaced a section at a time
Process optimization becomes a focus instead of repairs

Training is made easier with the available tools
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34
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35
Questions?
Land OLakes
PUBLIC
www.rockwellautomation.com
36

AP14 - Land O&#39;Lakes Modernization Increases Batch Througput ROKTechED 2016

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Land O'Lakes

Modernization Increases Batch Throughput, Cuts Days of Downtime

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Land O Lakes dairy co-op

Dairy foods division comprised of 11 facilities

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Cybertrol Engineering Overview

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Upgrade to the FactoryTalk

Server upgrade physical to

Business Challenge - 2009

Process Control Hardware Legacy system

PC operating systems needed updating

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

In with the NEW

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

HMI Redundancy Server Client system

Historical Data Logging and Archiving

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Business Challenge - 2009

Batching system proprietary system

System operated on clipboards

Source code not available for edit

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Information for Stakeholders

Rockwell Automation TechED 2016

Onsite Production Scheduling

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

User friendly operation screens with

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Business Challenge - 2009

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Business Challenge - 2014

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2016

AP14 - Land O'Lakes Modernization Increases Batch Througput ROKTechED 2016

AP14 - Land O'Lakes Modernization Increases Batch Througput ROKTechED 2016