A Multi-national Lube Oil manufacturer sets up green field facility near Mumbai for manufacturing of Lube Oils with Best in class technology for Batch Automation & Field integration with ASI bus technology resulting in faster time to market manufacturing large product variants.
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Challenge
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Existing plant was fully manual so no exposure to automation
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New Plant expected to be best in class for technology & automation for competing with Global MNCs.
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Faster time to market & highly flexible recipe management to take care of large product variants (500+ recipes)
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Due to wide geographical spread of the plant it was expected to use latest network technology up-to device level to optimize Field installation and cabling cost
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This being high volume low profit business plant operation expected to be at peak levels throughout (365 X 24 X 7)
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Solution
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Rockwell Process Automation system with Ethernet DLR as Network back-bone connected to various ASI Master modules located in field for field device integration
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Field mounted Rockwell make IP-67 VFD’s installed near the motors
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High end flexible Recipe management system based on specialized package for Blending plants – Auto-Blend
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Special Software features to reduce the batch cycle time and increase the through-put to maintain peak level production maximizing the plant asset utilization.
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Results
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Integration of Field devices & VFD’s on network resulting in reduction of overall installation time & cost of cabling & erection resulting in faster commissioning & reduction in overall project cost
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Proven & time tested recipe & batch management system – Auto Blend enabled faster & error free production start up leading to faster time to market
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Quick & fastest product changeover achieved due to the flexible recipe management system
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Accurate charging resulting in almost zero amendments
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Accurate Batch records & reports of Batch tracking