Challenge
Today’s manufacturers are trying to maintain operations while facing an increasingly costly workforce. The idea of growing capacity or throughput seems almost unthinkable when most are struggling just to maintain existing production levels.
Prima Frutta, a Linden, California-based cherry packaging facility, recognized that operational difficulties were preventing the packaging facility from fully utilizing all its production lines while operating at maximum capacity. Management determined it was time for an overhaul of their control system and systems integrator Automation Group of Modesto was called to help within a very tight timeline.
Solution
Phase 1 – Project Planning and Documentation of Equipment
The first step in the project was a collaborative planning, budgeting and documentation process between the Automation Group and Prima Frutta teams. By incorporating methodologies and standards from the Control System Integrators Association (CSIA), creating a detailed budget, and identifying and documenting all OEM hardware into schematics that were approved prior to proceeding to Step 2, the project would more easily stay on track and within budget.
Phase 2 – Wireless Network Setup
The Automation Group team set-up a wireless network which allowed 10 tablets to run the production line remotely using the Ignition industrial application platform from Inductive Automation. Ignition has become a top choice by integrators due to its flexibility, affordability, and fast set-up. Applications can be fully customized quickly and easily, and data can be accessed by tablet, desktop, or any other smart device to allow real-time data access from anywhere the user is located. For this project, the tablets could allow for a change in process flow from anywhere in the plant versus being in a static location, and provide full SCADA control. The process of installing Ignition on the tablets was seamless and took less than two hours. In addition to the tablets, the Ignition software ran on more than 120 screens throughout the plant to provide real-time data and color-coded information for employees to react quickly and efficiently.
Phase 3 – Development, Testing and Implementation
The Automation Group was able to utilize Prima Frutta’s existing server and develop both the integrated software and programmable logic controller (PLC) codes in a modular format so components, templates, and user-defined types could be reused for quick deployment.
Results
Automation Group created a virtual environment which mimicked the processes on Prima Frutta’s line so testing would not interfere with the actual line. Once testing and launch approvals were complete, Automation Group’s team migrated the changes to Prima Frutta’s server for a smooth transition that took less than a day. The project resulted in a 50% increase in production with no additional personnel which helped Prima Frutta grow to become the world’s largest cherry production line. The Ignition platform helped reduce downtime and enabled the cherry packaging facility to immediately and efficiently respond to changing conditions.
