Synopsis of Tobacco Processing/Cigarette Manufacturing Execution/Line Control System Transformation Program Project

Situation: A market leader in tobacco processing/cigarette manufacturing looked to maintain its strong position by revamping its existing controls automation and MES (Manufacturing Execution System) platform across its corporate enterprise. Issue: Existing technical platform was based on several disparate systems that were presenting challenges related to obsolescence, integration with SAP, excessive maintenance costs, limited flexibility for expanded functionality. Requirement: Standardized line control and MES solution for rollout to multiple facilities over multiple years. Brock Solutions' Role: Framework Study (included ROI Business Case; product evaluation/selection; Implementation Roadmap that addressed how and where to start the program to mitigate risks, optimize schedule, minimize disruption to personnel, etc.); determining cost and resourcing requirements; developing a comprehensive automation standard covering process definition, controls philosophy, system architecture, naming conventions, HMI, code and template libraries, program structure, documentation; replacing obsolete "CRISP" control logic (30,000 I/O) with new PLC/HMI platform; implementing and configuring a MES solution for performance monitoring, material management, quality management, and production scheduling; and interfacing the MES and controls and the MES and ERP (Enterprise Resource Planning) systems.

Main Technology Components: Siemens SIMATIC IT MES, Microsoft SQL Server, Rockwell PLCs, GE PLCs, iFIX HMIs. Interfaces to multiple 3rd party systems, including SAP, LIMS, CMMS, BW.

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