Driving Efficiency with Ignition SCADA

A leading Global 500 building products manufacturer sought to modernize operations at one of its U.S. manufacturing facilities. The primary objective was to increase production in the mixing area by improving scheduling efficiency and gaining better visibility into factors impacting Overall Equipment Effectiveness

(OEE).

The Problem

The manufacturing facility’s mixing plant relied on multiple standalone HMI applications and custom-built Visual Studio tools to manage operations, visualization, recipe management, quality control, and batch scheduling. This fragmented approach resulted in an unreliable, outdated, and difficult-to-maintain system that complicated troubleshooting and system management.

To address these issues, the project required weeks of discovery to identify all components and their functions before designing a fully integrated Ignition system. The new solution had to consolidate processes and interface with various controllers, including older Modicon Quantum and 984 models, some of which used unsupported communication protocols.

GPA's Solution

Multiple HMI’s, Databases and Visual Studio applications were spread out across the site. The challenge consisted of multiple weeks of discovery of components, and their functionality which needed to be captured, re-designed and implemented into a new integrated Ignition System. The new system would be required to interface with multiple controllers including older Modicon quantum and 984 controllers, some of which used no longer supported communication protocols. 

GPA led the research, design, and implementation of an integrated Ignition SCADA system that consolidated all existing subsystems into a single high-availability, modern distributed solution. This system seamlessly integrated with the existing infrastructure while introducing enhanced MES functionalities. The scope of work included:

• Process Visualization and Supervisory Control: Ignition SCADA provided a unified interface for monitoring and controlling the entire Mixing Area, replacing the scattered standalone WonderWare HMI stations

• Recipe Management: The existing custom Visual Studio application for recipe management was replaced with Ignition's built-in recipe management module, allowing for easier updates and better integration with other MES functionalities

• Batch Management and Scheduling: Ignition SCADA's scheduling capabilities were utilized to optimize batch execution and ensure timely production

• OEE Visualization: GPA built custom OEE functionality within the Ignition platform, delivering real-time insights into equipment performance and enabling the facility to identify and address inefficiencies.

• Security: The new system included enhanced security features to protect sensitive data and ensure compliance with industry standards

• Alarm and Event Management: Ignition SCADA's alarm and event management capabilities were leveraged to improve response times and reduce downtime

• Database Integration: All previously scattered databases for historization, alarms and events, scheduling, and recipe management were consolidated into a single MS SQL Server for centralized data management.

• Historization and Analysis: Historization, ad-hoc trending, and analysis tools were incorporated into a dedicated QA application fully integrated with the Ignition system.

• Network Conversion: The entire control network was converted to Modbus TCP, providing Ignition with seamless connectivity across the entire Process Control System.

Results

The implementation of Ignition SCADA resulted in significant improvements in operational efficiency and user experience. Key benefits included:

• Improved User Experience: The unified interface provided by Ignition SCADA made it easier for operators to monitor and control the entire Mixing Area, reducing the learning curve and improving productivity

• Improved Reliability: A single Ignition Gateway and Database system provides a modern, supported and centralized HMI which is easier to maintain, support, upgrade and expand.

• Enhanced Operational Efficiency: Real-time insights into equipment performance and optimized scheduling helped the customer reduce downtime and improve overall production efficiency

• Better Data Management: The integration of recipe management, batch execution, and data historization into a single platform streamlined data management and improved data accuracy

• Better Analysis Capabilities: Historical and real time data analysis tools like ad-hoc trending, and KPI dashboard provides operations with the resources to investigate their batch runs and optimize their processes.

• Increased Security: Enhanced security features ensured that sensitive data was protected and compliance with industry standards was maintained

Conclusion

The successful implementation of Ignition SCADA with Manufacturing Execution System (MES) capabilities demonstrated:

• The value of a unified, flexible platform in overcoming the challenges of a fragmented system

• Enhanced production and data management capabilities through batch execution and scheduling optimization

• OEE visualization with actionable insights to reduce inefficiencies and maximize asset and line performance

• Advanced alarm and event management that improved responsiveness, reduced downtime, and supported safer operations

• Fully integrated QA analysis tools that enabled deeper visibility into process performance

• The integration of robust security features to ensure compliance with industry standards and safeguard critical process data

  
  

GPA - Ignition SCADA Case Study.pdf

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