Project
PRJ-0239
Industry
Packaging & Consumer Goods
Application
PLC & HMI modernization
Commissioned
Oct 18, 2024
Status
Supported
Three lines moved from obsolete controls to a supported platform, each within a 48-hour window, with unplanned downtime down 41 %.
Project
PRJ-0239
Industry
Packaging & Consumer Goods
Application
PLC & HMI modernization
Commissioned
Oct 18, 2024
Status
Supported
Three lines moved from obsolete controls to a supported platform, each within a 48-hour window, with unplanned downtime down 41 %.
FIG. 1
PLC & HMI modernization
PRJ-0239
01
Commissioning results
Measured outcome
01
Commissioning results
Measured outcome
Unplanned downtime
61
→
36
h/month
3 lines · 6 months after cutover vs. same months prior year (−41 %)
Unplanned downtime
61
→
36
h/month
3 lines · 6 months after cutover vs. same months prior year (−41 %)
Mean time to repair
74
→
31
min
Controls-related stops · same period
Mean time to repair
74
→
31
min
Controls-related stops · same period
Format changeover
25
→
14
min
Average of 3 lines · HMI recipes replace manual settings
Format changeover
25
→
14
min
Average of 3 lines · HMI recipes replace manual settings
Longest cutover
46
h
Specified ≤ 48 h per line · 3 cutovers of 44–46 h
Longest cutover
46
h
Specified ≤ 48 h per line · 3 cutovers of 44–46 h
02
Engineering record
Challenge, approach and architecture
02
Engineering record
Challenge, approach and architecture
Challenge
Context. Three cartoning and case-packing lines installed between 1998 and 2004, running household products in 40 formats.
Existing process. Each line ran on legacy PLCs and text-display operator panels, with spare CPUs bought second-hand. Format changes were made from paper settings sheets, and only one technician could read the code.
Constraints.
No line could be down for more than 48 hours.
Machine safety had to be reassessed, not copied from the old logic.
Operators needed a familiar workflow on day one.
Challenge
Context. Three cartoning and case-packing lines installed between 1998 and 2004, running household products in 40 formats.
Existing process. Each line ran on legacy PLCs and text-display operator panels, with spare CPUs bought second-hand. Format changes were made from paper settings sheets, and only one technician could read the code.
Constraints.
No line could be down for more than 48 hours.
Machine safety had to be reassessed, not copied from the old logic.
Operators needed a familiar workflow on day one.
Engineering approach
We started with an obsolescence and documentation audit, then converted the logic to a structured standard and tested it against a simulation model of each line before cutover.
Scope. Logic conversion and restructuring; new pre-wired control panels per line; reassessment and re-validation of safety functions; new HMIs with format recipes; Ignition SCADA for alarms and downtime across the three lines; operator and maintenance training.
Engineering approach
We started with an obsolescence and documentation audit, then converted the logic to a structured standard and tested it against a simulation model of each line before cutover.
Scope. Logic conversion and restructuring; new pre-wired control panels per line; reassessment and re-validation of safety functions; new HMIs with format recipes; Ignition SCADA for alarms and downtime across the three lines; operator and maintenance training.
System architecture
Controllers: one S7-1500F per line, ET 200SP distributed I/O, 1,840 I/O points across the three lines.
Drives: about 46 drives re-parameterised and connected over PROFINET.
HMI: 15-inch panels per line with format recipes.
SCADA: Ignition server with alarm history and downtime reporting.
Safety: guard-door and E-stop functions re-specified and validated per line.
System architecture
Controllers: one S7-1500F per line, ET 200SP distributed I/O, 1,840 I/O points across the three lines.
Drives: about 46 drives re-parameterised and connected over PROFINET.
HMI: 15-inch panels per line with format recipes.
SCADA: Ignition server with alarm history and downtime reporting.
Safety: guard-door and E-stop functions re-specified and validated per line.
Deployment & commissioning
Panels were built and tested in our hall against a simulation of each line. Each line was cut over in one weekend: the first in 46 hours, the second in 45 and the third in 44. All three restarted at rate on the following Monday.
Open item: alarm rationalisation on line 3 is incomplete; 86 of 214 alarms remain to be reviewed with the client's operators.
Deployment & commissioning
Panels were built and tested in our hall against a simulation of each line. Each line was cut over in one weekend: the first in 46 hours, the second in 45 and the third in 44. All three restarted at rate on the following Monday.
Open item: alarm rationalisation on line 3 is incomplete; 86 of 214 alarms remain to be reviewed with the client's operators.
- AUDITAuditHardware, code, docs
- SIMSimulateLogic vs. line model
- FATPanel FATIn our hall
- CUTCutover≤ 48 h per line
- SCADAMonitorAlarms & downtime
03
Specification & results
Specification, acceptance and results
03
Specification & results
Specification, acceptance and results
Lines
Cartoning and case packing
3
Lines
Cartoning and case packing
3
I/O points
Across 3 lines
1,840
I/O points
Across 3 lines
1,840
Drives
PROFINET
≈ 46
Drives
PROFINET
≈ 46
Formats
As HMI recipes
40
Formats
As HMI recipes
40
Cutover window
Per line
≤ 48 h
Cutover window
Per line
≤ 48 h
Parameter
Specified
Measured
Result
Cutover duration
≤ 48 h
44–46 h
Pass
Cutover duration
Specified
≤ 48 h
Measured
44–46 h
Result
Pass
Safety function validation
100 % of functions
100 %
Pass
Safety function validation
Specified
100 % of functions
Measured
100 %
Result
Pass
Line speed at restart
≥ prior rate
Prior rate
Pass
Line speed at restart
Specified
≥ prior rate
Measured
Prior rate
Result
Pass
Alarm rationalisation
214 alarms reviewed
128 / 214
Open item
Alarm rationalisation
Specified
214 alarms reviewed
Measured
128 / 214
Result
Open item
Results
Measure | Before | After |
|---|---|---|
Controls platform | Obsolete, second-hand spares | Supported, documented |
Format change | Paper settings sheet | HMI recipe |
Unplanned downtime | 61 h/month | 36 h/month |
MTTR (controls) | 74 min | 31 min |
Results
Measure | Before | After |
|---|---|---|
Controls platform | Obsolete, second-hand spares | Supported, documented |
Format change | Paper settings sheet | HMI recipe |
Unplanned downtime | 61 h/month | 36 h/month |
MTTR (controls) | 74 min | 31 min |
04
Drawings
Layout and detail drawings
Original technical drawings prepared for this record. Illustrative, not to scale.
04
Drawings
Layout and detail drawings
Original technical drawings prepared for this record. Illustrative, not to scale.
FIG. 1 · Control architecture after migration
FIG. 2 · Phased cutover, three shutdown windows
We had three lines that nobody wanted to touch. Now my own technicians make the changes.
Engineering Manager
Client · consumer-goods manufacturer (anonymized)
PRJ-0239
05
Related
Solutions, platforms and resources
05
Related
Solutions, platforms and resources
A
Related solutions
B
Technology stack
C
Related resource
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