Case Studies

Ignition System for Machine Control and Analysis in the Medical Industry

Posted in HMI and SCADA, Manufacturing Automation and Intelligence, Medical and Pharmaceutical

Summary

DMC developed an Ignition SCADA system for our client to gather key metrics from several production machines, run various analyses on the collected data, and control the integration between the recipe system and PLCs to include raw material scanning. Our system adhered to 21 CFR Part 11 guidelines for medical production which requires an audit trail, part tracking, and more. In addition to those requirements, DMC provided extremely detailed reports on various manufacturing KPIs (key performance indicators), so the client could have a better view of their production line.

Solution

Our client worked in the medical industry and for one of their products, they developed a manufacturing line to fill various containers with liquid. They reached out to DMC to integrate an Ignition SCADA system into this production line. As an Ignition-certified integrator, DMC was well-equipped to meet our client’s needs. 

DMC’s team of expert HMI & SCADA engineers customized an Ignition system for our client that gathered data from seven machines. Each machine ran Ignition Edge and communicated its local machine data up to the main Ignition gateway. This allowed the system to automatically store and forward critical audit data and alarm information. In the event of a network failure, each machine could run on local machine control as well—making this system incredibly reliable.

Once the data was collected, various KPI analyses were automatically run. We developed a reusable library for calculating these key metrics, which allowed us to utilize the same script at both the machine and line level. This greatly cut down development and commissioning time, providing our client with a cost-effective solution.

In total, the Ignition system calculated twenty-six different metrics for each machine and the entire line, including OEE (overall equipment effectiveness) calculations. DMC developed a scheduler object for the line that allowed users to utilize these KPIs in tandem with scheduling operator shifts. For example, the user could schedule individual or recurring events, which Ignition would then use to automatically calculate key metrics for each shift.

Our customized system handled communication to the seven machines, as well as a remote recipe system. Therefore, DMC employed the Ignition sequential function chart feature to develop a state machine that ensured the remote system and the seven local machines were always operating synchronously with each other. In addition, we developed a material tracking system that logged all scanned materials in the line and would accept or reject them based on different criteria.

DMC’s solution not only increased the reliability and efficiency of the manufacturing line but also automatically gathered and analyzed key metric data. With the wide scope of recorded KPIs, DMC was able to provide our client with detailed reports of their machines. The client can use these reports to gain better insight into their production and make informed decisions to ensure a sustainable, profitable future.

Learn how DMC has helped upgrade other companies’ manufacturing lines and contact us today to get started on your next project.

Customer Benefits

  • Automatic gathering of KPIs from multiple machines
  • OEE calculations and analyses of the production line in Ignition
  • Reliable communication between line machines and remote recipe system
  • Extensive key metric reports for management
  • Automated material tracking system
  • Easy-to-use scheduler object for scheduling operator shifts and downtime