OSBL Detailed Design

Performed instrumentation and automation detailed design for OSBL facilities of an animal feed manufacturing plant, covering utilities and support systems outside the core process area. Deliverables included:

  • Control narratives / functional descriptions for OSBL systems

  • Instrumentation index, datasheets, and specification sheets

  • PLC/SCADA integration requirements and I/O mapping

  • Loop diagrams, termination drawings, and cable schedules

  • Control panel design inputs, installation details, and commissioning readiness documents

  • Network and communication interface definition for OSBL equipment and instrumentation

HMI RECOVERY

Challenge: The existing HMI suffered a display hardware failure, and the obsolete unit had to be replaced with newer hardware. However, the backup HMI application (running as a Windows 7 executable) could not run properly on the new system due to operating system compatibility differences, risking extended downtime.

Action: Assessed the executable’s dependency on legacy file paths and rebuilt the required directory structure on the replacement hardware. Mapped the new system’s folders to mirror the original Windows 7 file paths so the application could locate all required resources and configurations.

Result: Successfully restored and re-commissioned the custom HMI on the new hardware without requiring a full software rebuild, enabling continued operations and minimizing unplanned downtime.

Plantwide Program Backup and Documentation

  • Legacy automation hardware significantly increases the risk of unexpected downtime, especially in the absence of reliable backup files. With over 60 years of machine acquisitions from various OEMs, the client operates 376 systems in Plant 1 and 121 systems in Plant 2, composed of PLC and HMI platforms from multiple vendors—including Beckhoff, Siemens, Allen-Bradley, B&R, Mitsubishi, Panasonic, LG, Yaskawa, Omron, and Pro-face.

    A critical concern is that many of these systems lack updated or complete backup programs, making recovery extremely difficult in the event of failure. Combined with system diversity, aging components, and limited documentation, this exposes operations to prolonged downtime, complicated troubleshooting, and increased risk of irreversible data loss. In worst-case scenarios, the absence of backups can lead to extended production stoppages and significant operational disruption.

  • Immediate Stabilization Actions

    Backup & Documentation

    • Extract and archive all PLC programs, HMI projects, SCADA configurations.

    • Create standard directory structure

    • Ensure version control and restricted access.

    Temporary Spares

    • Identify currently functioning systems with common modules that can be interchanged as emergency spares.

    • Purchase refurbished/used critical cards for short-term continuity.

    • Phase 1: Audit & Backup – 3–6 months – No production impact

    • Phase 2: Obsolescence Pilot – 6–9 months – Weekend shutdowns

    • Phase 3: Network Upgrade – Parallel – Minimal disruption

    • Phase 4: Line-by-Line Migration – 2–3 years – Controlled downtime

    • Phase 5: SCADA Unification – 3–5 years – Parallel implementation

    • Backup & Documentation

      • Extract and archive all PLC programs, HMI projects, SCADA configurations.

      • Create standard directory structure

      • Ensure version control and restricted access.

    • Knowledge Transfer

      • Disaster recovery plan for each machine to avoid prolonged downtime during hardware failures

ASEPTIC FILLER

Challenge:
The aseptic filling machine exhibited intermittent seal deformation and leakage, resulting in compromised package integrity and an increased risk of microbial contamination during transportation. Replacement of critical components—including the heating element, sealing head, and temperature sensor—did not resolve the sealing defects. Additionally, the Siemens Comfort HMI had no available development backup, and access rights to critical process parameters were locked, preventing operational adjustments and troubleshooting.

Action:
Conducted a comprehensive analysis of the complete filling and sealing sequence, validating all step logic, interlocks, and process parameters directly through the PLC due to restricted HMI access. Retrieved and verified sealing parameters via PLC monitoring and diagnostics. After confirming parameter inconsistencies and access limitations, fully redeveloped and reprogrammed the Siemens Comfort HMI from scratch to restore proper parameter visibility and control. Configured secure but accessible operator-level permissions to allow controlled adjustment of sealing pressure, temperature feedback loop settings, and dwell time in accordance with the bag manufacturer’s sealing specifications. Subsequently calibrated and fine-tuned all sealing-related parameters to ensure process stability and repeatability.

Result:
Achieved consistent, uniform, and fully cured seals, eliminating occurrences of warped and undersealed packages. Restored full operational control of critical process parameters through the newly developed HMI interface. Reduced material waste and product losses due to seal rejection, and improved overall equipment reliability by minimizing unplanned downtime associated with sealing failures.

MES Integration & Data Acquisition

Challenge:
The plant required a reliable and structured method to collect real-time production data from multiple PLC systems and integrate it into a centralized MES platform. Existing systems lacked standardized data mapping, verified communication points, and readiness for seamless integration.

Action:
Performed comprehensive PLC program backups and validated all critical data points across key production systems (Preparation, Canning, Cooker & Cooling, and Palletizer). Confirmed active addresses, data formats, and memory locations, prepared MES-ready data tables, and executed full MES interfacing and integration. Conducted end-to-end data acquisition testing and validation to ensure system reliability.

Result:
Successfully implemented full MES integration across all targeted PLC systems, enabling accurate and reliable real-time data acquisition from multiple production lines. The solution now supports enhanced production visibility, monitoring, and data-driven decision-making aligned with Industry 4.0 initiatives.

Cigarette Maker

Challenge:
Following the replacement of the Festo valve cluster on the PROTOS cigarette maker machine by plant personnel, the system encountered persistent and intermittent faults that disrupted normal operation. The lack of proper documentation and uncertainty in the wiring and signal assignments made troubleshooting more complex. In addition, inconsistencies between the valve cluster configuration and the existing PLC logic created further challenges in identifying the root cause.

Action:
Performed an in-depth diagnostic assessment of the system, including verification of wiring integrity, signal continuity, and communication between the valve cluster and control system. Carried out detailed I/O mapping to reconcile discrepancies between the physical installation and the PLC program. Systematically tested each valve output and corresponding response, making necessary adjustments to ensure proper alignment. Coordinated closely with plant personnel to validate findings and ensure accuracy throughout the process.

Result:
Successfully eliminated system faults by correcting the valve cluster mapping and ensuring full compatibility with the control logic. The PROTOS machine was restored to stable and reliable operation. The resolution not only minimized downtime but also improved system understanding, reducing the risk of similar issues in future maintenance activities.

Cooling Tower Remote Control System Integration

Challenge:
The cooling tower system did not have remote control capability, limiting operators to local/manual operation. This restricted centralized monitoring and reduced overall operational flexibility.

Action:
Performed a comprehensive system assessment to design and implement remote control functionality. Integrated the necessary control signals with the RTU system and enhanced the PLC program to support reliable remote start/stop operations. Conducted thorough testing and validation, and completed full system backups to ensure maintainability and future support.

Result:
Successfully implemented remote control functionality, enabling operators to manage the cooling tower system remotely with reliable response. The upgrade improves operational efficiency, supports centralized control, and enhances system flexibility for modern automation requirements.