{"id":15302,"date":"2025-02-14T00:00:00","date_gmt":"2025-02-14T00:00:00","guid":{"rendered":"https:\/\/www.dmcinfo.com\/our-work\/s88-batch-architecture-implementation-using-pcs7\/"},"modified":"2025-09-05T13:27:04","modified_gmt":"2025-09-05T18:27:04","slug":"s88-batch-architecture-implementation-using-pcs7","status":"publish","type":"our_work","link":"https:\/\/www.dmcinfo.com\/our-work\/s88-batch-architecture-implementation-using-pcs7\/","title":{"rendered":"S88 Batch Architecture Implementation Using PCS7"},"content":{"rendered":"

After undertaking a large facility upgrade and expansion project, the client wanted to ramp up their new production capacity but was being held back by a poorly implemented DCS system. The client engaged DMC to first clean up the existing system and make it immediately more usable and reliable and then to rewrite the system following S88 best practices.\u00a0<\/p>\r\n\r\n

DMC first audited and updated the plant\u2019s interlock. During this process, DMC found several interlocks needed to be bypassed for normal operations and the majority did not serve adequate safety or protection purposes. DMC leveraged the built-in functionality of the PCS7 APL Interlock objects to link devices together so that operators could click on and navigate through the whole interlock matrix to see what was stopping them and why they were interlocked. This added clarity, reliability, safety, and insight into the system, so that the client could now run manually, if needed.\u00a0<\/p>\r\n\r\n

Once the batch rewrite in PCS7 was complete, DMC implemented a historian and batch reporting system in Ignition to provide better visibility into the plant\u2019s processes. We used OPC UA to pull data via the PCS7 WinCC 7 HMI using the PCS7 Connectivity Pack.\u00a0<\/p>\r\n\r\n

After experiencing the capabilities of Ignition, the client decided to add additional features beyond data collection and reporting. One of the client\u2019s goals was to streamline their data and document handling surrounding material shipping and receiving, which was previously managed through multiple manually maintained spreadsheets. DMC developed a custom integration to the client\u2019s LIMS systems to compile batch quality test data from multiple sources into a single database. DMC then developed integrations to PCS7 and the client\u2019s truck loadout system to automatically track and release batches for loadout and generate BOLs incorporating the batch quality data. In the end, the entire loadout process could be carried out on a tablet, including operator interfaces for loadout inspection and signoff signatures.\u00a0<\/p>\r\n\r\n

Learn more about DMC’s Manufacturing Automation and Intelligence<\/a> expertise and contact us<\/a> today for your next project.\u00a0<\/strong><\/p>\r\n","protected":false},"excerpt":{"rendered":"

After undertaking a large facility upgrade and expansion project, the client wanted to ramp up their new production capacity but was being held back by a poorly implemented DCS system. The client engaged DMC to first clean up the existing system and make it immediately more usable and reliable and then to rewrite the system […]<\/p>\n","protected":false},"author":8,"featured_media":15301,"template":"","meta":{"customer":"New Leaf","summary":"

DMC worked with a client in biodiesel production to implement an S88 batch architecture using PCS7 with the goal to reduce operator errors, collect better batch data, and provide robust fault tolerance and minimize downtime. DMC also integrated the PCS7 DCS with an Ignition system custom developed by DMC that provided high-level process overview, data collection and historization, batch reports, shipping and receiving tracking, LIMS integration, and Bill of Lading generation. <\/p>\r\n","description":"","customer_benefits":"