Overview

A global manufacturer of lithium batteries sought a track & trace Manufacturing Execution System (MES) for a facility that had 61 work cells across three production lines. The goal was to establish a comprehensive system for data collection, management, and reporting within the battery production facility. ITG identified and monitored around 61 distinct work cells or zones that required oversight for product tracking, KPIs, OEE metrics, and time-series data logging.

Solution Delivered

After examining the specified requirements, ITG delivered a Manufacturing Execution System (MES) that included the following functionalities:

1. Product Tracking

2. Key Performance Indicators (KPIs) and Overall Equipment Effectiveness (OEE)

3. Process Historian

4. Reporting Portal

Each of these four subsystems ran on its own server-class computer. To align with the customer’s existing automation platform, ITG implemented a seamless and scalable solution using off-the-shelf software products from Rockwell Automation, featuring FactoryTalk technology. This enabled the customer to efficiently maintain the system using in-house resources.

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Product Tracking and Logging

The product tracking and logging involved monitoring events at each work cell through the ControlLogix PLC and storing relevant data into a Microsoft SQL Server database. ITG utilized the S95 standard to minimize costs, risks, and errors involved in setting up interfaces between enterprise-level and production control systems. Event triggers were initiated either by barcode readers, buttons on the existing line HMI screens, or any status changes in the ControlLogix PLC at each work cell. These triggers logged events, recorded the date and time, and saved up to twenty product- and process-related tags. ITG later integrated traceability to the Enterprise Resource Planning (ERP) work order and product genealogy. A dedicated server hosted this database, and reports were accessed using a web browser.

KPIs and Overall Equipment Effectiveness (OEE)

ITG’s solution incorporated Rockwell Automation's FactoryTalk Metrics to deliver reports on downtime, KPIs, and OEE dashboards. FactoryTalk Metrics monitored each work cell and provided precise, timely, and detailed information on work cell performance, along with a comprehensive machine event history. This data formed the foundation for identifying the true causes of inefficiency, waste, lost capacity, and equipment states. Reports were web-based and required no specialized software on the user's end. A dedicated server hosted the FactoryTalk Metrics database.

Conclusion

By leveraging standard software components from Rockwell Automation, the customer was able to maintain the system efficiently using their in-house resources, thereby avoiding the complexities of mastering proprietary systems or programming languages. Reports were designed to display product tracking details and offer the capability to drill down into various related Batch and Lot elements, providing the customer with the insights needed to optimize their production process.

For more details or to discuss how ITG can support your manufacturing needs, please Contact Us.

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