The client and challenge
Our client, an internationally-known appliance manufacturer, was experiencing problems with its Manufacturing Execution System (MES). The MES was intermittently losing data from the plant floor production equipment after implementation, leaving gaps in the production data. With a plan to extend this implementation across other plants, it was imperative to have the first plant successfully running. EASi was invited to investigate the reasons and develop a solution for the data loss.
The EASi solution
To solve the problem, EASi provided an on-site team with various technical disciplines. Our team provided PLC programming and networking support, Kepware ServerEX OPC programming and technical writing to capture the solution. In addition, EASi:
- Recommended and installed several components of the MES system to improve response times
- Made network cabling changes to meet published network protocol
- Adjusted various IO server network configuration parameters that eliminated packet loss
- Utilized EASi’s programming guideline containing best practices for PLC code implementation, and developed additional programming aids
- Developed client-specific guidelines for implementation of the MES system to other plants
- Provided a list of recommended equipment, applicable reference manuals and testing procedures at four different phases to ensure solid network performance and optimized network configuration parameters
EASi provided a recommendation to replace several components of the MES system with components that improved response time by 25 percent. EASi adjusted IO Server network configuration parameters, reducing lost packets to meet client specifications. And by EASi providing technical guidance, resources and documentation, the customer was well positioned to roll out the implementation across four additional plants.
OPC Server Configuration