A series of automated tests is performed on each frozen beverage machine, and data is collected and stored in a centralized database.  For each test step, the system sends commands to the product’s CPU through digital communication.  The product’s response to the command is measured and recorded using pressure, temperature, voltage, and current sensors.  Each result is compared to allowable test limits, and a pass/fail determination is made.  Upon test completion, a full report is automatically generated and sent to a network printer.  A web-based reporting system allows supervisors to immediately view test status and results remotely and respond quickly to problems.  Historical data is logged, providing a key tool for ongoing process improvements.

Learn more about our Test & Automation Solutions for Food and Beverage and contact us today for your next project.

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DMC later revisited the client’s facility to develop architecture for their confectionary equipment and implement it in a second confectionary facility. It was an improvement on the custom equipment code. This allowed the client to expand to another refining line at the second facility with the custom control system DMC developed.

Most recently, DMC was involved with developing a third facility for the client based on the existing background technology DMC had developed previously for the first two facilities. DMC used the existing architecture and applied it to the client’s specific configuration of refining lines and ingredient systems. This was beneficial for the client because the cost of development for a new refining line was lower compared to rebuilding the technology from the ground up. DMC frequently traveled onsite to assist with the startup of the facility and continued to add new features and new flexible options, allowing the client to make changes on their own.

When the third facility experienced an IT issue that caused limitations on receiving diagnostics, DMC wrote a C# application to collect the recipe information integrating with the SQL database to obtain recipe information that provides better diagnostics.

DMC’s expertise in WinCC Professional and SQL database qualified us to provide a modern upgraded solution and successfully reuse and update existing background technology for the third confectionary equipment facility.

DMC’s work on the client’s three confectionery equipment facilities allowed the client to expand and add new tanks, add new ingredients, reduce the cost of refining lines, and utilize a more flexible code base.

Learn more about our Manufacturing Automation and Intelligence expertise and contact us for your next project.

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MD4IoT goes beyond monitoring computers on a network. It can scan, detect, and report on OT equipment such as PLCs, HMIs, VFDs, and more. This information is aggregated into a local dashboard on the MD4IoT appliance and in the Azure dashboard for the product. It is ingestible by SOC software like Service Now (SNOW), Splunk, and LogRhythm.

DMC’s client reached out to get AD4IoT implemented at their various sites across the globe. We implemented the program in four phases: Discovery, Design, Deployment, and Operationalization.

Discovery

DMC began by collaborating with the client site and their third-party vendor to remotely gather information from the client’s existing network. We developed a questionnaire, and the answers helped us to determine the type of network the client used, the types of devices used, and the number of devices on that network. Our discovery included switch diagnostic information, which allowed developing detailed network diagrams and device relationships.

Design

Using the information gathered during the discovery phase, DMC built a map that plotted the connections between switches at each site. Once we had a thorough understanding of how each switch was connected, we created switch configurations to route OT traffic via SPAN/RSPAN to the central manager.

RSPAN was used for the distribution switches and SPAN was used for traffic mirroring to the sensor. We then developed commands for the sensor that was to be installed. The sensor is a local AD4IoT instance that aggregates traffic and sends data to the global central manager instance of MD4IoT used for reporting.

Deployment

Next, DMC installed the MD4IoT operating system, which is Ubuntu based, on the client-provided Dell R350 PowerEdge Server at each site. There were three network ports to configure on the server: one that was used for AD4IoT Management, one used for ingesting SPAN data, and one used for Dell server administration (iDRAC).

We reconfigured their network by adding around 15 – 20 configuration changes for each distribution and core switch. To minimize risk and issues that are likely to occur in OT Networks such as the high traffic caused by high-definition cameras, we performed thorough testing.

Operationalization

DMC then made improvements to the monitored targets and subnets that the SPAN brought in. We also applied alert filtering to reduce anomalies and false positives in reports. Any alert determined to be a false positive was cleared and filtered so that future alerts provided the most meaningful data.

Each server was connected to a central manager, which allowed the client to access data from multiple sites via a single pane of glass. DMC then conducted administrator training for IT and OT personnel so that they could operate the AD4IoT sensor appropriately.

Learn more about DMC’s Microsoft Azure Cloud Solutions and Services expertise and contact us today for your next project.

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Architecture

Many of the existing pieces of equipment either had no PLC or had a PLC that was obsolete and no longer supported. DMC selected upgraded PLC hardware and drives to modernize the existing equipment and provide PLC control to equipment that was previously only run manually.

Safety System Implementation

Prior to our work, each piece of equipment could only be run standalone. As a part of this project, the equipment needed to either run standalone or be integrated into a single production line depending on the product they were going to make. In order to safely integrate the equipment into a single production line, the e-stop associated with each piece of equipment needed to be added to a single safety zone.

To accomplish this, DMC specified and procured safety PLCs, safety I/O cards, and PowerFlex 525s with integrated safety. This allowed us to use programmable safety logic and, depending on the selected production line configuration, programmatically add or remove a system’s equipment from the global estop zone. This safety communication was done wirelessly to allow for the varying line configurations. 

Panel Build

For some of the equipment, an additional panel was needed to add controls or to fit the additional safety hardware if the original panel was out of space. Our Control Panel Design and Fabrication experts from our UL Certified DMC Fabrication Studio stepped in and created Rockwell-based panels for the pilot plant. DMC’s in-house electrical design team, along with a trusted partner, provided the modified and new electrical schematics required for this project.

Since we were working with older equipment, new information was often uncovered during the design upgrade. DMC’s Fabrication Studio allowed us to change the system’s design on short notice while still accommodating the client’s timeline throughout the project.

Conclusion

DMC was flexible throughout the project as design changes were required, and we worked through global supply chain delays.

We left the client with a modular production line with an integrated safety system that contains equipment capable of running standalone or as a configurable unit. We also provided them with upgraded and modernized Rockwell hardware for new and existing enclosures.

DMC is a Rockwell Gold System Integrator. Learn more about our Rockwell expertise and contact us for your next project.

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DMC used Inductive Automation’s powerful Ignition platform, including purpose-built MES software modules from Sepasoft, to develop a custom MES application that added key automated features to the client’s production workflow and helped to better integrate their various software systems.

DMC created an algorithm that performs multiple sortation and grouping steps to optimize the order in which the client’s crops are planted. This routine increases the efficiency of the harvest by grouping crops together. It also organizes transplant operation by considering future transplants and harvests when deciding where crops should be planted, setting the customer up for future efficiency gains. DMC developed several web API integrations with an ERP system to coordinate production information with the customer’s enterprise needs.

To collect inventory data, DMC connected the MES application to an InfluxDB timeseries database – a type of NoSQL database.  RFID scan data was retrieved from InfluxDB and used to track individual parts as they moved through the transplant and harvest process. This provided the client with finely detailed information about the locations of parts in the facility. In some cases, DMC connected the application directly to the RFID scanners and weigh scales to measure part-by-part crop yields.

By integrating with the ERP and InfluxDB database, the customer received detailed information to help with their decision making. This allowed them to optimize the use of their equipment and increase product throughput.

Learn more about DMC’s MES Programming services and contact us for your next project.

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The final step was creating a UI to meet customer specifications regarding front-end recipe management, which involved creation, deletion, import, export, and modification of recipes. The UI also included user management and allowed the client to download recipes to the PLC through AVEVA Wonderware.

This solution streamlined and simplified the client’s recipe editing and management process. It allowed users to input recipes without requiring their presence on the factory floor.

Learn more about DMC’s Application Development expertise and contact us for your next project.

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DMC began the design process by working closely with the client to determine all requirements for their new system. Once the objectives were fully defined, DMC developed a custom MES using Sepasoft modules. The Sepasoft modules gave DMC the base functionality for the system. DMC’s engineers then customized the modules to fit the client’s specific requirements.

The major functionality of the system is scheduling production runs and tracking data against those runs. This increases the visibility of the production floor and gives the client data that can be used to improve their processes.

To achieve this, the system communicates with a variety of systems including the Ignition SCADA Gateway, WMS, custom vision system (through RESTful APIs), corporate inventory, and line equipment. In total, the system gathers data from 25 lines and collects around 50,000 data points per shift.

The captured data allows the MES to calculate OEE, downtime, production yields, and labor. Personnel from operators to plant managers to the FSQA department can then use these reports to gain greater visibility into production and make informed decisions about their business.  

Learn more about DMC’s MES expertise and contact us for your next project.

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To meet the aggressive customer timeline, DMC leveraged two major tools available with the Siemens Brewing Template. The first tool was Siemens TIA Openness, which allowed DMC to rapidly generate the base control module, or device, layer of the program. By doing this, DMC was able to go from zero to full manual control of devices in a matter of days, as opposed to weeks. The second tool leveraged was SiVarc, which allowed DMC to automatically generate HMI screen objects based off of the control modules created through the Openness utility. The use of SiVarc greatly reduced HMI screen development time, allowing DMC to focus on the less automated portions of development (for example, sequence creation).

To allow for operational flexibility in running and creating new recipes, DMC implemented an S88 software structure to create separation between the equipment and procedural layers. Because of this, the system can be run in three different modes of operation: manual mode, semi-auto, known as, equipment module mode, or full automatic batch control mode.

Learn more about DMC’s Siemens partnership and our work in the Food and Beverage industry. Contact us with any project inquiries. 

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The client came to DMC with a request to enhance the reliability of their machine controls. Their original automation platform was not well-known and was running on a PC as opposed to a PLC. If the computer crashed, it would stop production. At a facility that processes close to 1000 cuts an hour, 5-10 minutes spent rebooting a system could result if substantial losses in output. DMC converted the machine to a Siemens S7-1500T PLC with S120 Servo Drives while maintaining all the original system functionality. This not only allowed for improved reliability but also guaranteed global technical support with Siemens integrators located worldwide. These features aided our client in selling to their end customers and speed up future commissioning.

In addition to enhanced reliability, DMC built a flexible code base with parameters that can be adjusted directly from the HMI. This meant that the machine could be easily modified to create custom-tailored solutions for each factory installation.

Within a year of commissioning the first machine, DMC has now built 5 additional machines that are deployed around the world. With ongoing requests coming from the end clients, DMC’s flexible code is quickly modified to meet customer’s requests. One example of this is when DMC was able to install an entire machine in one day. This short deadline was able to be met due to the benefit of consistently using one platform throughout the machine.

In the meat industry, precision while cutting is a high priority. When a few inches in the wrong place could result in wasting an expensive cut of meat, DMC needed to be able to increase accuracy. By integrating the Kinematic Technology Object into the client’s machine, future users can make more complicated cuts with increased accuracy.

Learn more about DMC’s work in the food and beverage industry and our Siemens expertise. Contact us for any project inquiries. 

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The customer’s existing system was only able to generate pass/fail results for a single product at a time. DMC’s support was requested because of our extensive experience with vision applications and image analysis routines. The TriSpectorP gave DMC the flexibility to measure and record actual data of entire batches to quantify the results of the Quality Assurance process.

SICK’s custom programming environment and built-in API suite allowed DMC to rapidly develop a program to extract actual measurements and generate batch reports.

The intuitive user interface allowed the customer to adjust the settings of the image acquisition process to maximize the performance of the system.

SICK also has a separate software package called AppManager which allowed the customer to store and deploy different programs to their TriSpectorP without having a development license.

The customer was so satisfied with the results of the analysis for a single image of the product that they requested additional features be added to the system. In order to increase the size of their sample batch, they requested we add the functionality to report results of multiple images. We were also able to easily add new analysis routines for other product types to the system because of the flexibility provided by the programming environment of SICK AppStudio.

Learn more about DMC’s work for the food and beverage industry and our vision inspection expertise. Contact us for project inquiries. 

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