Challenge
“If you fail to plan, you are planning to fail”. This quote by Benjamin Franklin emphasizes the importance of site surveys for industrial environments. With time, money, and resources on the line, site surveys act as a crucial first step to plan for maintenance, spare parts, upgrades, and mitigate the risk of unplanned downtime. This critical information was needed by a leading American food distributor to better understand the health of their plant’s automation infrastructure. E Tech Group was engaged to thoroughly assess their automation hardware and operational technology (OT) networks and provide a comprehensive site assessment report. This report would clearly identify risks and opportunities as well as crucial steps to upgrade and strengthen their automation infrastructure.
Solution
The customer’s plant had three buildings which included over 500 control panels. E Tech Group analyzed numerous factors and data points to determine areas of risk and opportunity across their plant. This included the lifecycle of parts that are currently being used on the production floor as well as the equipment’s life cycle positioning ranging from active to end of life. E Tech Group’s certified professionals also evaluated existing processor types and quantities across the plant and documented the customer’s OT network infrastructure.
The data collected from the site assessment was then organized and analyzed to serve as a roadmap for facility improvements. E Tech Group formulated a comprehensive, well-structured report for the customer’s management, engineering, and maintenance teams which outlined upgrade recommendations and a clear timeline to implement these upgrades based on the priority level.
Results
E Tech Group worked closely with a plant electrician to complete an on-site assessment of all control panels and OT networks in less than eight weeks. The data from the site assessment was used to provide a comprehensive report outlining automation infrastructure by area, OT network architecture, obsolescence, and recommended paths forward to modernize. The site assessment resulted in a proactive plan to reduce the customer’s likelihood of future controls hardware failures and provided a clear roadmap to strengthen their automation infrastructure.
In today’s increasingly interconnected world, it is more important than ever to ensure that your IT and OT systems are secure and reliable. The results of an IT/OT assessment can help you identify and prioritize any security risks that need to be addressed. The assessment can also help you develop a plan to improve the security of your IT and OT systems, and identify areas for operational improvement, such as bottlenecks and inefficiencies. How does an IT/OT Assessment work? What is the process? How does E Tech Group manage the process? And how do we break it down into an easy 1, 2, 3 process? Step 1: One-to-two-day site visit photographing and documenting all panels and line OT assets – regardless of manufacturer – and running a facility IT network scan. Step 2: Collect, analyze, and grade all IT and OT Assets for security vulnerability & obsolescence. Information presented back in an interactive Asset workbook and comprehensive written report. Step 3: Client meetings with management and operations to review the data and discuss remediation plans. An IT/OT Assessment can prove an invaluable tool for a company facing operational difficulties, security breaches, or reliability in their automated processes. By understanding what’s right in your IT and OT systems – and what’s not – you gain the tools necessary for us to create a secure, custom automation system for your current and future needs. Learn more about IT/OT Assessments: the process, the benefits and how E Tech Group can be your partner through it all!
E Tech Group Senior Project Manager, Cassy Gardner was a panelist for the ISPE San Francisco first-ever Food Science Technology event. The diverse set of panelists dove into all things Food Science and Technology; covering topics from the perspectives of Design and Construction professionals to the views of frontiers within Food Technology companies. About ISPE: The International Society for Pharmaceutical Engineering The ISPE is a non-profit that aims to advance all sectors and stages of pharmaceutical engineering by providing research and automation professionals with educational, technological and networking resources. ISPE was founded in 1980 by professionals addressing the need for an organization that focused on practical applications of pharmaceutical science for technical professionals. The San Francisco Bay chapter has been a particularly active and prolific ISPE member since its founding in 1991. About E Tech Group: A Leading Nationwide Control System Integrator E Tech Group has deep domain expertise in the food and beverage industry, including automation for alternative proteins, recipe, batching, continuous production, and more. Coupled with our extensive experience in pharmaceutical automation, we are poised for the future of automation in food science technology and industrial food production. Thank you Cassy and all those involved with the event for sharing your knowledge and insight on the industry!
Challenge
Production health is a synergy between availability, performance, and quality. Overall equipment effectiveness (OEE) is the gold standard to measure these metrics and can help identify early signs of production issues with modern software solutions. This was the challenge for a leading supplier of almond products who needed to find a better way to monitor the real-time efficiency of their lines as well as record production line problems as they occurred. The almond supplier also wanted to own this data and not rely on outside data hosting resources since these often limit extensive data archives. E Tech Group was engaged to upgrade the almond supplier’s performance monitoring system given their experience with the platform, OEE, and database structures.
Solution
The almond supplier requested E Tech Group convert their existing production system to Ignition, an industrial application platform from Inductive Automation, to standardize their SCADA architecture due to its scalability and intuitive design features. The customer requested the project be expedited within a very tight timeline and E Tech Group was ready to put boots on the ground.
E Tech Group provided connection programing to ensure assets were properly tracked in the Allen-Bradley PLCs using Studio 5000 Logix Designer in addition to the Ignition system using the Perspective module. This supported the customer’s ability to have a personalized visualization system that could monitor, control, and record their industrial applications in real-time across any mobile device.
The E Tech Group team set up a database that could effectively log information in an organized manner and enabled seamless data extraction. This structure was difficult to develop from scratch due the high-level of efficiency desired when querying the data. The E Tech Group team engaged their Ignition specialists to configure and connect the SQL database structure with Ignition’s transaction groups and this was later proved to be highly efficient.
Result
The project was completed in three months and the Ignition Perspective module is currently being tested by the customer. The project deployed seamlessly given E Tech Group’s proactive collaboration with the almond supplier. The Ignition platform enabled the customer to track shift start and end times as well as monitor the shift time efficiency. E Tech Group’s Ignition specialists leveraged their in-depth expertise to support the conversion to the Ignition platform, enabling a strong performance monitoring system that could properly track, store, and visualize data to support the customer’s OEE.
