Optimizing Chemical Packaging Lines: Upgrades for Uptime & OEE Tracking

The customer’s chemical packaging line was experiencing intermittent delays. The customer wanted to identify issues, maximize line uptime, and integrate a better OEE tracking system for their chemical packaging line.

Industry: Chemicals

Client: Fortune 100 Chemical Company

KEY ENGINEERING FEATURES:

• Rockwell FactoryTalk Metrics integration for fault code tracking
• PC-Based reporting system for OEE tracking and downtime metrics
• Full chemical packaging line evaluation with mechanical and automation recommendations

CORE CHALLENGES:

• Line faults for existing OEE tracking were not integrated in one central database, making troubleshooting difficult
• Frequent line stoppage issues caused by both mechanical problems and conflicting line controls needed to be corrected to drastically reduce downtime

INTEGRATED CANNING LINE SOLUTION:

EPIC completed a thorough review of the entire filling and chemical packaging line, identifying automation issues and problems with key equipment. Several chemical packaging line changes were recommended and implemented:

• Different conveyor speeds relieved issues by creating proper feed rates for machinery

• PID loop was tuned and a pump VFD problem corrected. These issues caused filler downtime due to inconsistent flow during hot and cold weather
• Upgraded PanelView and recipe corrections in the batching HMI
• The existing OEE system did not include centralized reporting. EPIC added Rockwell FactoryTalk Metrics to the chemical packaging line.  Fault codes were reported for all equipment in a centralized PC output for line operators

• Faults were added for all equipment; including conveyors, filler, case packer and a depalletizer. These faults were aggregated to provide additional data for ongoing proactive downtime issue resolution

• A laser date coder was purchased but never installed on the chemical packaging line. EPIC successfully integrated the new date coder, causing a dramatic effect on speed

IMPACT:

• Supervisors were able to identify fault codes and recurring line problems faster with an aggregate view of issues through FactoryTalk
• Major mechanical errors, that caused frequent line stoppage, were identified for immediate correction
• Throughput was maximized with better line balance, allowing a smooth product flow without major product backups or shortages from one equipment piece to the next