The Challenge
Huhtamaki required a multi-lingual, paperless shopfloor MES to automatically inform operators, shop floor management and internal transport personnel on tasks, status, background and general production information to enable them to do their job efficiently. The system also required the shop floor personnel to report back, inform and alarm peers, shop floor management and other (non-production) staff in an easy, efficient and reliable way.
The overall goal was to eliminate paper as an information carrier and generate an agile and flexible basis for running the Moulded Fiber production plants.
Our Approach
NeoDyne delivered a Multi-lingual Paperless Shop floor MES consisting of a Data Processing Engine, Microsoft SQL Enterprise Database, Integration Services application and .NET Front end.
We adopted an agile approach involving the agile design, development, build and test of individual modules. These modules included:
- Job Management/Scheduling
- Finished Goods Recording
- Product Labelling
- Multi-lingual
- PLC Settings
- Logsheets
- Quality
- Consumables Tracking
- OEE
- Equipment Downtime
- Schedule Adherence
- Document Management System
- Preventative Maintenance
- Near Miss Reporting
About Huhtamaki
Huhtamaki Fiber Packaging is a global producer and supplier of fiber and pulp-based packaging for fresh food and beverages. The fibre packaging division of the Huhtamaki group is active in 10 operating countries with 11 plants across the globe.
In 2016, NeoDyne assisted Huhtamaki Netherlands with the replacement of an existing ‘bespoke’ MES platform, built on a Delphi platform, with a modern supportable platform built on latest Microsoft.Net technologies.
The solution leveraged a Wonderware System Platform interface engine and Kepware IO Servers to communicate with Shopfloor machines, robots and other systems.
The project was part of a much larger rollout of a new Epicor ERP system across the enterprise, with our solution forming an integration gateway between ERP, automation systems, third-party warehouse management systems, and existing plant performance monitoring systems.
Customer Requirements
- Seamless ERP and third-party application integration
- Eliminate Paper as an information carrier
- Enable two-way communication between operators and management etc on plant operations including Downtime etc
- Multi-language front-end application
- Flexible Electronic Logsheets
- Integration with site automated palletising systems
Challenges
- Defining a standard integration mechanism which could be repeated for all systems
- Delivering a standardised solution with the flexibility to meet site-specific requirements
- Developing a standard for application development to enable quick and easy translation without the need for code changes between sites
- Developing a standard Electronic Logsheet module with fully configurable, site-specific content without the need for code changes
Outcome
- Established common integration “touch-points” to all external system types including ERP, and labelling systems
- Developed a concept of a standardised “Core” application, with a series of site specific “Localisations”
- Implemented language translation resource files which are easily maintained and updated
- Developed a standard logsheet form, with dynamic content, managed via a relational database schema
- Examined automation system source code and implemented changes to facilitate robust and reliable integration
Other Case Studies
See other System Integration projects below to see our solutions in action
MSD Brinny
Design, supply and commission of a new Clean Utilities and Process Control System for a brownfield contract manufacturing plant.
Lakeland Dairies
Automation control system and associated MES modules for a new Lactose extraction and drying plant.
