Summary

ITG was delighted to collaborate with a major Corrugated Paper Manufacturer to enhance data collection and analytics capabilities across their plant. As part of Customer’s larger initiative to integrate advanced data collection in all 31 locations, this project aimed to extend those capabilities to the all the facilitites..

Achieved Goals and Overview

The primary objective of this project was to improve operations by gathering and analyzing critical data from the plant. ITG successfully delivered engineering, programming, hardware/software, and installation services to integrate both existing controllers and new sensors into the Customer AWS Data Lake.

The integration involved utilizing existing network controllers, supplemented with added WiFi modules and Remote I/O. These elements collectively fed data into a local controls network that connected to a SORBA SDC Virtual Machine (VM). This VM then transferred aggregated data points to the Customer AWS Cloud via an MQTT Broker, approved by the Customer IT team.

Services and Deliverables

Discovery

1. Conducted an extensive onsite discovery to collect essential information for sensor selection, physical installation methods, and coordination with plant personnel.

2. Reviewed existing controller programs to validate the sensor and tag lists.

3. Delivered a comprehensive plan and schedule for the subsequent design, build, and installation phases.

Design

1. Selected all necessary components for installation, along with detailed installation instructions.

2. Coordinated with Customer’s plant and IT personnel to finalize networking requirements.

3. Produced a network topology map, a Bill of Materials (BOM), and identified any deviations from the original Request for Proposal (RFP).

Build

1. Modified existing PLC programs to accommodate new Remote I/O equipment.

2. Configured the SORBA SDC VM, which was then installed at the local Circleville IT closet by Customer’s IT team.

3. Procured, assembled, tested, and shipped all Remote I/O cabinets to the Circleville site.

Installation and Commissioning

1. Installed all equipment according to the accepted design and used a Customer approved electrical installer for controls instrumentation and wiring.

2. Commissioned modified PLC programs and configured new remote I/O and networking equipment.

3. Validated the successful data transmission from the Circleville site to the Customer AWS Data Lake.

Timeframe

The installation process was completed within the projected timeframe of 10-12 weeks following the receipt of the order.

For further information about this successfully completed project or potential future collaborations, please Contact Us.

At ITG, we take pride in turning data into actionable insights. Your operational efficiency is our commitment.

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