Real Time Production Tracking

Malisko Engineering, Inc was asked to provide a Multi-Module System including SPC and Quality Tracking, Line Performance Tracking, and Downtime Tracking for a multi-national eye care products company.  The system monitors multiple sterile fill packaging lines.

Mockup

SPC:

  • Logs Quality Data and AQL Sampling for up to two simultaneous batches running on the same line.

Line Performance:

  • Performance Data is tracked by shift allowing for shift comparisons.
  • Performance Indicators are tracked and calculated.  Results are stored in an OSIsoft PI Data Historian.

Downtime:

  • For Manually Caused Downtime events, operators choose from seven (7) downtime categories and numerous specific cause codes under each category.
  • The system tracks Automatic Downtime Causes and records the cause and duration without operator intervention.  Each downtime cause is logged to a database with time/date stamp, line #, category, cause, and duration.

Engineering Tasks & Services

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  • Involved in developing the concept, architecture, capital budgeting and detailed designs.
  • Wrote User Specifications, Functional Specifications and Detailed Design Documents.
  • Designed, programmed, tested, and verified wiring.
  • Validation and Production support.
  • Integrated Intellution iFix SCADA, Microsoft SQL Server, OSIsoft PI Data Historian, ControlNet, Remote I/O, Siemens S5 & S7 PLC's (Profibus to Ethernet), Allen-Bradley SLC-500 & ControlLogix PLC's (Ethernet).
  • Interfaced to existing SAP system to upload and download quality data.
  • Production and Maintenance training with a User's Manual for the System.