Installation of a new process control system with a connection to an ERP system

For a chocolate manufacturer, our partner company SPIE ESCAD Austria replaced an existing, old process control system with a new process control system featuring a connection to an ERP system.

Challenge and Objective

The company was looking for a way to better manage its increasingly complex quality controls and production processes. The existing process control system could no longer keep up with the higher requirements. In addition, many investments in production facilities were pending, which were to be integrated into a new process control system right away.

A week was defined during which production was to stand still. Within this time window, “Area 2” (mixing and preparation) of production was to be switched over to the new process control system.

Solution

First, a project team was formed with experts from SPIE ESCAD Austria and our customer. After in-depth discussions with the operators, the production manager, and quality assurance employees, the exact function of the systems was determined and a functional specification document was created.

The subsequent software preparation took place in-house at SPIE ESCAD Austria. The customer’s IT team provided the necessary hardware requirements to install our system.

The creation of the interface to the ERP system presented a challenge that required intensive discussions and testing. Before we began the first changeover, the production employees were trained on the new system.

On two weekends before the planned shutdown week, we checked whether all systems worked with our system. On Sundays, the legacy system was reactivated. During the shutdown week, we carried out the final system tests and started the first test productions on the third day.

The operators were also brought in very early on. After all, with such a comprehensive changeover, it is always important that the production employees are satisfied with the new system and can identify with it.

Benefits

The customer now benefits from a reliable, technologically advanced system that centrally collects and processes all relevant process data and makes it available to the corresponding positions within the company. Furthermore, with SPIE ESCAD Austria, the customer has a partner who is available around the clock (24/7 hotline) and can therefore minimize system downtime.

These strengths of our partner company SPIE ESCAD Austria were utilized

Experience with the Proleit process control system
Expertise in switching systems over to new platforms with minimal downtime
Proactive approach, e.g., by involving employees who will be working with the new systems in the changeover process. This ensures a higher level of identification with the "new."

About our customer
Our customer is a well-known chocolate manufacturer with high quality standards for its processes and products.

Industry
Food production

After the installation of the new process control system, we integrated further production areas so that all areas now run via our system. In a recent conversation with the customer, he confirmed to me once again that it was the right system and the right partner, and that this remains the case.

Thomas Neudorfer
Project Manager
SPIE ESCAD Austria GmbH

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