Wärtsilä – Production control system in an industrial plant
Implementation of a production control system (BI-TAL) that allows digitizing production management processes in the factory, eliminating paper records and providing real-time information on the status of manufacturing, aimed at facilitating plant decision making.
IoT | MANAGEMENT SYSTEMS | DIGITALIZATION
INDUSTRIAL STARTING POINT
Wärtsilä, a world leader in intelligent technologies and complete life cycle solutions for the marine and energy markets, has an ERP management system (SAP) where it manages orders, production orders (POs) and the routing of activities associated with each PO. It also has several databases that compile historical production data from data collected manually in the plant. The exploitation of these databases is carried out a posteriori in Excel.
This operation presents several problems that the company intends to solve:
- Information not available in real time. All the information collected on paper is dumped to the databases on a daily basis, so the company does not have a real-time picture of the production situation.
- High presence of paper in the plant. Staff time dedicated to the preparation, completion and subsequent processing of work reports and checklists.
- Absence of a detailed analysis of production incidents (stoppages, non-conformities, indirect work of plant personnel,…).
- Non-centralized databases, in Excel and Access, which are difficult to interconnect and easy to expand.
SOLUTION AND IMPROVEMENTS ACHIEVED
ITCL Centro Tecnológico proposed the integration of a production control system (MES) in its plant located in Cantabria.
The integration of the system facilitates the execution and decision making of the plant or production manager, with the ultimate goal of increasing productivity, reducing non-productive times of the process.
Among the main objectives of the implemented MES system, the following stand out:
- Implementation of a Production Operator Panel, from which all valuable information associated with production is recorded, reducing paper records in the plant and eliminating data entry tasks in other applications and archiving of records.
- To have a tool to monitor the process and status of the production system in real time, thus facilitating its supervision and management.
- Integrate a Planner – Sequencer of all operations, to have a production plan that is visible and shared by all departments of Wärtsilä.
- Keep a real-time record of the main raw material and consumables consumption associated with production, as well as the availability of certain auxiliary elements (molding boxes).
- To have a joint and unique database that allows to automatically generate reports and performance and productivity indicators and to exploit plant production data.
- Automatically collect data from the spectrometer, in order to associate the corresponding information to each casting.
Figure 1. Diagram of the BItal MES System at WÄRTSILÄ
SOFTWARE ELEMENTS OF THE SYSTEM
At ITCL we have developed an adaptable and customizable production control system for each industrial plant.
The following modules have been implemented in Wärtsilä:
- BI-TAL management application:
The Bital software module is a tool that allows the comprehensive management of all production processes in the plant. It is specifically designed to be used by those responsible for factory management and control.
BITAL allows the execution of plant data query processes in real time, as well as access to historical data and production indicators previously parameterized.
All the information is available in any computer with access to the plant network, with the appropriate methods of information protection by means of access limitation.
- BI-TAL Operator Panel (PO)
The operator panel is the application used by production personnel, located next to the machines and assembly stations. It allows the display and input of information manually to the BITAL system. In addition, the operator panels are a communication system with the operator, where all the necessary information for the execution of OFs can be displayed.
It is an easy to use application, thus favoring the implementation of the system in the plant and providing the necessary agility of use of the system by the personnel.
- BI-TAL Sequencer
The sequencer tool has two main functions:
- Facilitate the work of the person in charge of planning the OFs, having a graphic tool for the allocation of each OF and its phases in the available calendars of each machine or section.
- To facilitate the launching of the OFs to the plant operator panels, for production control.
- Import of customer orders from available databases.
- Validation of orders by technical office.
- Sequencing of production orders
- Start of the production phase of the manufacturing order (personnel assigned at each moment).
- Management of molding tasks (start, end, incidents, molds used, equipment,…).
- Casting management (parts assigned to each casting, temperature, expected load, corrections, load carried out, slag management,…).
- Management of machining, measuring, finishing and dispatch tasks (start and end of OF, verifications to be performed, workstations used,…).
- Generation and completion of quality checklists in PO.
- Management of non-conformities.
- Identification of consumables used in each OF.
- Real time monitoring.
- Allocation of hours to indirect jobs.
- Verification of parts by the person in charge.
- Manufacturing history consultation.
- Indicators, reports and control panel
- Work parts
- Casting report
- Part associated information
- Customizable reports
The project has been developed in different phases and continues to evolve in a process of continuous improvement, adapting to the needs and priorities of the company at all times.
In this way, 3 main phases were implemented. Once each of them was implemented, they were validated by the Wärtsilä personnel involved in the project and laid the foundations and requirements for the following ones:
- Phase 1: production management.
- Phase 2: checklists, non-conformity management. New reports.
- Phase 3: sequencer implementation.
ROLE OF ITCL
The following works have been developed by ITCL:
- Performing the requirements analysis together with Wärtsilä staff.
- Structuring and adaptation of Bital Management Application (with unlimited users).
- Structuring and adaptation of Bital Operator Panel for Wärtsilä positions and sections.
- Adaptation of Bital Sequencer: visual tool for sequencing of OF’s.
- Server configuration: Internet Information Server, installation of SQL Express, Net Core and installation of the developed applications.
- Proposal of components supply with associated cost.
- Proposal of server adaptation to Bital’s requirements.
PARTICIPATING COMPANIES AND PROFILE
Diego Martinez – firstname.lastname@example.org