wonderware customer success stories

CUSTOMER SUCCESS STORIESWONDERWARE SOFTWARE SOLUTIONS AT WORKENABLING REAL-TIME SUCCESS

Wonderware Mobile Solutions

Integrate the fieldwith the management team.Harness your mobile workforce foraligned business success.Getting your workforce in sync with your bottom line objectives takesmore than an electronic clipboard. You need a complete workflow anddata management solution that captures and enforces the best operationalpractices out there in the field. Configurable out of the box, the WonderwareIntelaTrac® System makes it easy to for your field workers to focus onthe right priorities and ensures that their safe operational proceduresmatch today’s challenging business goals. Go to Wonderware.com andget a FREE White Paper on how you can rapidly harness your mobileworkforce to help improve your bottom line.

©2009 Invensys Systems, Inc. All rights reserved. Invensys, IntelaTrac and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners.

www.wonderware.com/mobile

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EditorialEnabling Sustainable Success..........................................................................................................................5

AutomotiveBRiSA Bridgestone Sabancı Lastik Sanayi ve Ticaret A. - Turkey .............................................................6Gates Power Transmission Ltd. - United Kingdom .....................................................................................9Grupo Antolin - Spain............................................................................................................................... ....13Magna Automotive - United Kingdom.........................................................................................................17Schaeffler KG - South Africa .........................................................................................................................21

ChemicalsBayer CropScience AG - France..................................................................................................................25sia Abrasives Industries AG - Switzerland .................................................................................................28

ConstructionDiGeronimo Aggregates - USA ...................................................................................................................31

Facility ManagementLogitek, S.A. - Spain ............................................................................................................................... ........35National Security Technologies, LLC - USA..............................................................................................39The Venetian and Palazzo Resort Hotels & Casino - USA....................................................................43

Food & BeverageAmadori Group, GESCO Consorzio Cooperativo - Italy ...................................................................47Coca-Cola Fortune (Pty) Ltd. - South Africa ............................................................................................51Elledi S.p.A. - Italy............................................................................................................................... ............55Frito-Lay Gıda San. ve Tic. A. - Turkey ........................................................................................................58Huys Voeders N.V. - Belgium........................................................................................................................61Lotte SamKang Co., Ltd. - Korea ................................................................................................................65New Belgium Brewing Company - USA....................................................................................................68Orley Foods (pty) Ltd. - South Africa .........................................................................................................71OSM Piatnica - Poland............................................................................................................................... ....76The South African Breweries Limited - South Africa ..............................................................................79

Metal ProductsAlcoa Inc. - Spain ............................................................................................................................... ............83Hoco Chrome V.O.F. - The Netherlands .....................................................................................................87Otefal S.p.A. - Italy ............................................................................................................................... ..........91

Mining AngloGold Ashanti Limited - South Africa.................................................................................................95Assmang Limited - South Africa ...................................................................................................................99

Oil & Gas

Chevron Oronite Company LLC - France.............................................................................................105

PharmaceuticalsCambridge Reactor Design Ltd. - United Kingdom ..............................................................................109

PowerBodycote plc - USA ............................................................................................................................... .....113Eskom Holdings Limited - South Africa ...................................................................................................117S.T.E. Energy S.p.A. - Italy ...........................................................................................................................121

Process Engineering Meteng Pty - Australia ............................................................................................................................... .125

Pulp & PaperLenzing - Austria ............................................................................................................................... ...........129

TransportationTecnositaf S.p.A. - Italy ...............................................................................................................................133Transports Publics de la Région Lausannoise (tl) SA - Switzerland ..................................................137

Water TreatmentComunidad de Regantes de Motril-Carchuna y Cota 2000 - Spain ................................................141Global Water Management, LLC - USA..................................................................................................145Ontario Clean Water Agency (OCWA) - Canada...............................................................................149Puerto Rico Water and Sewage Authority - USA ................................................................................153Tragsa (Empresa de Transformación Agraria, S.A.) - Spain.................................................................156

Wonderware Representatives ..................................................................................................................162

CONTENTS

It may not be a corner office,but the impact will be just as great.

Accelerate your career withWonderware Mobile Solutions.

Configurable out of the box, the Wonderware IntelaTrac® System can empower you to become an integral part of the business decision-making process. Don’t just collect data with a clipboard–become a key player in achieving operational goals. Catch issues early–before they become bigger problems, while helping to save substantial production and maintenance costs. Break away from the tedium by being a part of a more streamlined workflow. Make your mark,using a powerful solution that supports safe operations, savings andvalue that you help create every day. Go to Wonderware.com andget a FREE White Paper on how an empowered mobile workforcecan help improve your company and your career.

©2009 Invensys Systems, Inc. All rights reserved. Invensys, IntelaTrac and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners.

www.wonderware.com/mobile

WNDR-787 MobileBlue-WW_A4.indd 1 17-06-2009 9:50:30

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Dear Reader,

Welcome to the 2009 collection of Wonderware SuccessStories with the focus on Enabling Sustainable Success.

Sustainable success takes two forms. The first is therecognition that our world has finite natural and human resources and both ofthese must be properly sustained. The second form of sustainable success isyour career and business success. It is important that you invest in yourself andyour company to ensure long term, sustainable success. This is what drives us toinnovate new and better ways of doing things every day. Our mission is todeliver software solutions that empower the success of a wide range ofproduction workers in the Operations Management market space. In thiscollection of stories, you will discover proven examples of people being able todo their jobs better with faster agility, real-time collaboration and decisionsupport. Production workers are inclusive not only of plant and facility operators,but also their supervisors and managers, as well as the IT staff that manages theIT infrastructure on which these software solutions run, along with otherapplications that integrate with Wonderware software. Production workers alsoinclude all of the quality, safety management, maintenance and engineering staffs.

Over 570,000 licenses of Wonderware software solutions are in use in over125,000 locations in 181 countries in the world. This is an amazing testimony tothe widespread applicability of our open software platform for a wide range ofmanufacturing and infrastructure operations. But the numbers only become trulysignificant when we enable others to innovate for their personal and businesssuccess. That is what this book of success stories is all about – sharing innovativeapproaches that were used to help drive real world business success.

When we enable our customers and partners to innovate new ways ofperforming their work better, faster, less expensively and greener - they are onthe fast track to achieving sustainable operational excellence for their businesses.

I would like to thank all of the customers and partners in this most impressiveissue. I also invite our readers to challenge and engage with us in ways thataccelerate our mutual innovation in support of sustainable success for a brighterfuture.

Wishing You Every Opportunity for Success,

Mark DavidsonVice President, Global MarketingInvensys Operations Management

Company Overview

About Wonderware

Wonderware (www.wonderware.com) is the marketleading software solutions and ecosystem brand forreal-time operations management software andassociated ecosystem partners providing solutions for:Supervisory HMI (Human Machine Interface),GeoSCADA (Supervisory Control and DataAcquisition), Mobile Operations, ProductionManagement, MES (Manufacturing Execution System),Performance Management, EMI (EnterpriseManufacturing Intelligence), and integration with assetmanagement, supply and demand chain and ERP(Enterprise Resource Planning) applications.Wonderware is a brand offering of the OperationsManagement Division of Invensys.Invensys Operations Management is a leadingprovider of automation and information technologies,systems, software solutions, services and consulting toglobal manufacturing and infrastructure industries.Headquartered in Plano, Texas, its solutions are used bymore than 40,000 clients around the world in over200,000 plants and facilities. Invensys OperationsManagement solutions include control andmeasurement instrumentation, safety critical anddistributed control systems, a wide range of real-timeoperations management software and professionalservices that help its clients design, operate andmanage the safety, efficiency, productivity, sustainabilityand profitability of their assets and operations. Invensys clients are some of the world’s mostimportant industrial organizations - large oil refineries;chemical, gas, LNG (Liquefied Natural Gas), power,pharmaceutical and mineral processors; food andbeverage companies; metals and mining companies;water and wastewater facilities; pulp and paper mills -and its solutions deliver significant cost benefitsassociated with the secure, efficient operation ofindustrial plants and facilities. Invensys OperationsManagement’s other offerings are delivered underseveral prominent industry brands, including: ActionInstruments, ArchestrA, Avantis, Barber-Colman,Continental Industries, Eurotherm Chessell, EurothermControls, Foxboro, IMServ, InFusion, SimSci-EsscorandTriconex. The company’s approximately 10,000employees and global partner ecosystem integratethese products and services to help clients collaborateacross people and systems in real time - to make faster,better decisions and synchronize their operations fromthe plant floor to the executive offices, aligningproduction goals with business objectives. Invensys is headquartered in London and is listed onthe London Stock Exchange (ISYS.L), withapproximately 25,000 employees working in 60countries.

For more information, visit www.invensys.com.

EDITORIAL

Automation Solutions /// Automation Solutions /// Automation Solutions ///

What goes upand down

at the same time?

Productivity and Costs.Increasing productivity and lowering costs is a tough challenge and one that was faced by a large engine manufacturing group. Working with their specialist integrators, the group’s team built a state of the art production facility in Dundee, Michigan, USA. Here, hundreds of Mitsubishi CNC controllers, PLCs, HMIsand servos were integrated to make a single e-F@ctory where systems operated together to create large volumeproduction, lower rework and overall lower costs - in factup to $100 million dollars lower cost are claimed by the customer.

You may not be producing automobile engines but youcan still benefit from Mitsubishi Electric’s high octane Automation Solutions.

Mitsubishi Electric: Making e-F@ctory work for you.

www.mitsubishi-automation.comFor those who want to know more.

Industry: Automotive, General Process Manufacturing

BRiSAwww.brisa.com.tr

“Now, operators are able to concentrate ontheir work. Efficiency has been increased sincethey now focus their energy on increasingperformance and productivity”.

Yaman Yazgan, Project Manager, BRiSA

Wonderware Helps Turkey’s BRiSA Tire Factory Achieve HighQuality, Productivity and Efficiencyby EST (Enerji Sistem Teknolojileri Sanayi)

Goals:• Implement a Manufacturing Execution System

(MES) to help increase product quality andmanufacturing efficiency and eliminate manual datacollection and reduce production procedures.

Challenges:• Inconsistency in the manual collection of the plant

data affecting the plant’s efficiency and productquality;

• Develop a clear upgrade path for the MES systemto enable improvements as technology evolves.

Wonderware Solution:• ActiveFactory software;• InTouch HMI;• Wonderware Historian;• Wonderware Manufacturing Execution Module.

Results:

• Significant increase in productivity;

• Huge improvement in lot traceability;

• Previous hard copy of archived information now avail-able with just the touch of a button;

• Huge improvement on quality;

• Increased Operators’ Efficiency.

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“Now, operators are able to concentrate ontheir work. Efficiency has been increased sincethey now focus their energy on increasingperformance and productivity”.

Yaman Yazgan, Project Manager, BRiSA

Izmit, Turkey – BRiSA is thenumber one tire manufacturerin Turkey and the sixth biggesttire producer in Europe. BRiSA operates the largesttire factory in the world,operating under one roof, aswell as being one of Turkey’squality leader. BRiSA has implemented the‘Shop Floor Project’ in order torealize a Manufacturing ExecutionSystem (MES) to help increasing product quality toits top.

The Quest for Consistent High Quality

Initial project studies started in 2001, followed by aFunctional Analysis phase, a Pilot Application phase, aTest Implementation, Execution and Commissioningphase, the project ended in 2008. The project is themost comprehensive MES project in Turkey.

For the Shop Floor project, BRiSA adoptedWonderware software solutions to realize datacollection process, to send set point values tomachines, and analyze production and machineperformances.

The Shop Floor project was defined to manage theproduction at BRiSA factory.

As other global large companies, BRiSA utilizes thesystem to follow up their production, in order tomaximize their production quality. The applicationsoftware aims data collection, as well as setting theprocess parameters for the machines and recordthe downtime values of the machines. One of themost important data is the inventory information.Real time stock data is updated when materials areutilized, hence users can see what product, semiproduct or raw materials are used, and where, for agiven time instant. The Project also includes thequality control system. Process parameters used forproduction can be followed up in real time. It ispossible to retrieve the historical data of materialsfor a product. The most important phase of theproject is the machine integration. Data qualityincreased, since machines produce the data andstore it to the sofware automatically.

Culture Change for the Factory

Before the deployment of the MES Project, allproduction reports were created on paper. Thisincluded production plans, setpoints, alarms andother plant data. The manual recording ofinformation on paper by operators resulted in a lotof inconsistencies. It was difficult for the operatorsto collect information and operate the plant at thesame time. Once the fully-automated Wonderware-based MES was installed, all inconsistencies anderrors were reduced and efficiency improved. Theautomation enabled the operators to focus inproducing products because the previous manualoperations, such as work order and production datacollection, became automated. BRiSA projectmanager Yaman Yazgan states: “We have managed toimprove our manufacturing in two main categories: First,we had a big increase in productivity, due to theautomation of the previous manual data collection.Operators, now, have access to accurate information;inconsistent data coming from different sources hasbeen eliminated. Second, we have improved in lottraceability. Before the project, we had to bring a lot ofpaper from the archive and, now, we receive the sameinformation with just the touch of a button”. “Operator’s errors at the plant have been almostcompletely eliminated. This has resulted in a hugeimprovement on quality”, Yazgan continues to tell thatthe best result of all is the change in productionculture. “Now, operators are able to concentrate ontheir work. Efficiency has been increased since they nowfocus their energy on increasing performance andproductivity”.

Wonderware Walks with BRiSA through theTechnology Waves

Bimsa, Wonderware system integrator in Turkey, isthe preferred partner of BRiSA because of theirlong working relationship over the years and theexperience in plants’ production and manufacturing.Turkish Wonderware Distributor, EST Enerji hasbeen working with BRiSA and Bimsa for more thanten years, providing support for the currentinstallation. They are poised together as BRiSA looksto adopt the Wonderware System Platform in thenear future.

This document was realized thanks to the support of: BRiSA and Bimsa, Wonderware system integrator.

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ActiveFactory software, InTouch HMI, Wonderware Historian, Wonderware Manufacturing Execution Module.

Automotive, General ProcessManufacturing

Industry: Automotive, General Process Manufacturing

Gates Power Transmission Ltd.www.gates.com

“With the help of Wonderware software, we havebecome a leading company in time-to-market, on-timeperformance, meeting customer expectations and cost-base reduction. We win our orders on quality. The levelof performance our customers receive from theproducts leads them to buy from us.”

Roddy Edgar, IS Manager, Gates Power Transmission

Wonderware assists efficient production of automotive and industrial beltsby Wonderware United Kingdom

Goals: • Create an Enterprise Manufacturing

Intelligence system with real-time bi-directionalintegration from disparate shop floor toEnterprise Resource Planning level.

Challenges: • The plant had different hardware and software

solutions, making it difficult to acquire datafrom different technologies that are spreadacross the world.

Wonderware Solution: • ActiveFactory software;• InBatch software;• InTouch HMI;• QI Analyst software;• Wonderware Historian;• Wonderware Manufacturing Execution Module.

Results: • Real-time bi-directional integration from disparate

shop floor Programmable Logic Controller systemsright up to Enterprise Resource Planning level;

• Ease of use of Wonderware software solutions andcomprehensive training provided by WonderwareUnited Kingdom enables Gates’ staff to carry outongoing in-house enhancements to the system;

• Winner of the Best Engineering Plant in the UKaccolade at the 2008 Best Factory Awardssupported by Cranfield University and WorksManagement magazine.

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Dumfries, Scotland – The Gates Corporation hasbeen recognised as one of the leading manufacturersof automotive power transmission products since itsinception in 1911. Gates employs some 38,000personnel worldwide of which 6,400 are dedicatedto Power Transmission.

Gates is a geographically diverse corporation withlocations throughout the world. The European HQfor Gates Power Transmission is in Erembodegem,Belgium, and manufacturing sites are located inDumfries, Scotland; Aachen, Germany; Nevers,France; Balsareny, Spain and Legnica, Poland. Some390 staff are located in Dumfries, working four shiftsround the clock to produce 500,000 belts a week.

The Dumfries facility manufactures synchronousbelts and couplings for the automotive and industrialmarkets. The site produces everything from thesmall belts found in food mixers to large industrialbelts utilised in ski lifts and farm machinery. Gatessupplies most of the major automotive customerswith OEM (Original Equipment Manufacturer)products and also produces aftermarket spares. The industrial side manufactures belts for everydayequipment such as vacuum cleaners, cash dispensersand automatic doors.

Gates Dumfries facility also produces Poly Chain®polyurethane belts which replace conventionalchains on motorbikes for customers such as Yamahaand Kawasaki. Custom belts are also produced for

bicycle manufacturers and industrial applicationsusing Gates Poly Chain® GT® Carbon™ high-torque drive systems.

Improving Efficiency of Production Processeswith Wonderware

A corporate initiative saw the introduction ofInTouch HMI (Human Machine Interface),

Wonderware Manufacturing Execution Module andWonderware Historian software in 2000, and threeyears later, QI Analyst software was introduced forstatistical analysis. Gates implemented a new globalproduction system in 2004 and this initiativecombined with Wonderware technology has helpedto improve the efficiency of production processes.

“We wanted a window on the manufacturingprocesses,” says Roddy Edgar, MIS Manager atDumfries. “There were two sides to this need – wewanted visualisation, to see what was happening and wealso wanted history and analysis of data to enablepossible improvements in quality. In addition, weobtained traceability and lot control using our MESsolution based on the an Wonderware ManufacturingExecution Module software-based MES solution.”

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ActiveFactory software, InBatch software, InTouch HMI, QI Analyst software,Wonderware Historian, Wonderware Manufacturing Execution Module.


2000

InTouch HMI andManufacturing Execution

Module introduced

2003

Wonderware Historianintroduced for statistical

analysis

2004

Global production systemintroduced, the

combination withWonderware improvesproduction efficiency

2006

Gates operates with 3.5days inventory, down to15 hours and unit costs

have fallen by 3.5%

2008-9

Gates wins numerousindustrial awards

Figure 1: Belt Quality Control.

A key issue was the need to acquire data fromdifferent technologies. “There were differentProgrammable Logic Controllers, different EnterpriseResource Planning systems, and different technologiesspread across the world,” says Edgar. “For example, weuse Allen Bradley systems in the US and Siemens inEurope. We have an IBM mid-range AS400 EnterpriseResource Planning system running in Dumfries.”

The Wonderware solution provided Gates with real-time bi-directional integration from disparate shopfloor Programmable Logic Controller systems rightup to Enterprise Resource Planning level.

“We are now at the point where users see real benefitsfrom using the systems in their day-to-day work.Enhancements are now pulled by users because theireyes have been opened by the power of the system,”says Edgar.

Against this, there are the European drivers in thatsales and marketing, forecasting and budgeting are

handled at the European HQ near Brussels. The trends in Dumfries will be comparable to thoseon similar machines in the different countries inwhich the company operates.

Major Benefits

The Wonderware software solutions involvingInTouch HMI, Wonderware Manufacturing ExecutionModule, Wonderware Historian, QI Analyst software,ActiveFactory software (the front-end system forWonderware Historian), and InBatch software wereprovided by Wonderware United Kingdom and SwiftAutomation.

The ease of use of Wonderware products andcomprehensive training provided by WonderwareUnited Kingdom enables Gates’ staff to carry outongoing in-house enhancements to the system. Dumfries also utilises InBatch software to control abatch process producing water-based adhesives used

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Figure 2: Belt production.

Figure 3: Inspection.

in the production process. InBatch software controlsthe entire batch process providing full traceability ofrecipes, equipment and materials.

Key AchievementsGates Production Systems have evolved over time,and indeed are continually evolving. “We utilise a cellmanufacturing process, so we can commissionWonderware on one cell and then later, start on anothercell,” says Edgar. “There is great flexibility withWonderware, we can install different products atdifferent times but still integrate everything togethercreating a total solution.”

Introducing the Gates Production System in 2004has resulted in more efficient operations.Improvements to material flow have added furthersavings. At the start of 2006, Gates operated with3.5 days inventory – it is now down to 15 hours andother improvements have reduced the need forworking capital. As a result of the new system, unitcosts have fallen 3.5 per cent.

“We use Wonderware for improving the quality of ourproducts and also for error proofing the manufacturingprocess”, says Edgar. “The system gives visibility on theprocess at all levels in the organisation. This enablespeople to make faster decisions and improve the qualityof the process”.

That Gates Power Transmission has made greatstrides in its work at Dumfries can be proventhrough its winning the Best Engineering Plant in the

UK accolade at the 2008 Best Factory Awardssupported by Cranfield University and WorksManagement magazine, and being HighlyCommended in the Supply Chain award, sponsoredby Toyota.

This document was realized thanks to the support of: Gates Power Transmission.

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Figure 4: Finished product.

Industry: Automotive

Grupo Antolinwww.grupoantolin.com

“The Performance solution and ArchestrAarchitecture allowed us to develop a scalableOEE system by using all the functions of aSupervisory Control and Data Acquisition(SCADA) system. Because of this, there hasbeen a reduction in development time.”

André Brandão, Project Manager, Sysmaker

Grupo Antolin Lusitânea optimises its production processeswith Wonderware solutionsby Wonderware Spain

Goals:• Improve the efficiency in order to respond to

higher volume demands;• Optimise efficiency in one specific assembly line to

later replicate it on other production lines.

Challenges:• The system needs to be implemented without any

shutdown to the existing production lines.

Wonderware Solution:• InTouch HMI;• Wonderware Performance software;• Wonderware System Platform.

Results:• Visibility of line efficiency, showing opportunities for

process improvement. Grupo Antolín now has greatvisibility in the efficiency of its Lusitânea productionlines. The critical data is used to analyse new waysto improve the process;

• Seamless integration with current control systems;• Low impact on shop-floor operation, due to

automatic work order synchro and data collection.

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“The Performance solution and ArchestrAarchitecture allowed us to develop a scalableOEE system by using all the functions of aSupervisory Control and Data Acquisition(SCADA) system. Because of this, there hasbeen a reduction in development time.”

André Brandão, Project Manager, Sysmaker

Vila Nova de Cerveira (Lusitânea), Portugal -Thanks to Wonderware technology, Grupo Antolinhas achieved great improvement in efficiency andquality in one of the production lines of its Lusitâneaplant, obtaining critical information to study newpossibilities in real-time improvement and decision-making.

Leading Spanish Multinational in its Sector

As the leading Spanish multinational in the designand manufacture of components for car interiors,Grupo Antolin focuses its strategy on integralservices that include the conception, design,development, manufacture and distribution of carroofs, doors and seats. With a global turnover ofapproximately 2.2 billion euro in 2007, a presence in22 countries with 86 plants and 20 technical/salesoffices, Grupo Antolín has over 10,000 professionalsworking to ensure full customer satisfaction. The group’s origins date back to 1950. It has a bigorganization doing research and development, usinghighly qualified personnel and the most advancedtechnologies capable of adapting to client needs.Grupo Antolin offers multi-technological products,thanks to its expertise in materials, advancedsimulation techniques, electronics, industrialprocesses, safety, acoustics and vibration.

In Search of Optimum Efficiency

Grupo Antolin Lusitânea has implemented aWonderware solution for its factory located in thetown of Vila Nova de Cerveira (Lusitânea - Portugal)with the aim of optimising the efficiency of itsproduction lines.According to Rui Araújo, Production DepartmentDirector at Grupo Antolin’s Lusitânea plant: “Theautomobile sector is becoming more demanding; To beable to respond to the demands of our clients, we neededto improve the efficiency of one our assembly lines,especially the one dedicated to assembling door locks.This is why we decided on technological change throughthe adoption of the latest generation software.” The company was looking for a solution that couldbe integrated without interfering with theproduction line. It was then that they contactedSysmaker, a Wonderware ArchestrA-certified system

integrator. Sysmaker created a PLC solution thatgathers information from all field variables. They alsodeveloped a complete Overall EquipmentEffectiveness (OEE) system based on WonderwarePerformance software. All the data is collectedthrough the PLC from the different equipment onthe assembly line. This includes all detectors, sensors,pneumatic and electric system controls, alarms,separation of OK/notOK parts, management ofmanufacturing model changes and accounting ofmanufactured amounts. The Wonderware solution isessential in helping to compile, store, process andorganize the required information that interactswith the PLC system by translating the data itreceives into an understandable format.

“The aim is to implement Wonderware technology in theline for door lock assembly and then to replicate it lateron other production lines. In the end, to have standardOEE (Overall Equipment Effectiveness) in all thelines” adds Araújo. The OEE solution helps tomeasure the production efficiency of industrialmachinery and it involves monitoring all essentialproduction parameters. These parameters are basedon availability (real-time functioning of theproduction machine), usage (real productionobtained in comparison with forecasts during thefunctioning time of the machine) and quality (numberof good pieces obtained).

A Complete, Personalised OEE SystemThe implementation of the software began afterSysmaker carried out the corresponding test phase.The Wonderware software complied with all the initial

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InTouch HMI, Wonderware Performance software,Wonderware System Platform.

Automotive

Figure 1: Real time efficiency according to diagram of specific times.

demands set by Grupo Antolin by providing the latestgeneration solution and integrating it into the plantwithout interference. It also added a very importantelement: the ability of adapting to client demands. Consequently, a complete OEE analysis system wasimplemented in accordance with the requirementsof Grupo Antolin’s Lusitânea plant.

The application is based on WonderwarePerformance software, a scalable solution thatallows the addition of new functionalities such astraceability, genealogy, execution of job orders,control of intermediate stock and man-hourmanagement. The software is a component ofWonderware Enterprise Manufacturing Intelligence(EMI) and it includes functions that facilitatecomplete OEE monitoring. The system is able toidentify areas of improvement, such as small stopsand low production speed that affect performance.

A Unique, Integrated Platform

Grupo Antolin has implemented a Wonderwaresolution to obtain a shared platform of industrialapplications that can run on practically any existingsystem. Wonderware System Platform provides aunified environment that facilitates plant visualisation,historization, communications and integration ofother industrial automation applications.

Full Functionality and Scalability Wonderware System Platform is built on ArchestrAtechnology, an innovative architecture for plantautomation and information based on a real-timeService Oriented Architecture (SOA). This makes itpossible to reuse existing automation applications.

“The Performance solution and ArchestrA architectureallowed us to develop a scalable OEE system. Because ofthis, there has been a reduction in development time”explains André Brandão, Sysmaker Project Manager.“The Wonderware Historian on the other hand, compilesand stores all the plant information, providing full visibilityof the data that enables correct decision-making,” pointsout the manager of Grupo Antolin’s Lusitânea factory. The Wonderware Information Server uses MicrosoftSharePoint and Web Part technologies to presentand collect production and plant performance dataon the Internet or the company’s Intranet. GrupoAntolin professionals at the Lusitânea plant accessthe information and make informed decisions in realtime, thus helping to detect errors beforehand. Thissaves on costs and improves staff efficiency.The last element of this innovative platform isWonderware InTouch HMI (Human MachineInterface), which is outstanding for its usability andease of use. The HMI helps to control all the factoryprocesses in an intuitive, clear and descriptivemanner. “The Wonderware staff helped Sysmaker topersonalise and make the specific required changes forthe PLC programme and the Performance database,”concludes Brandão.

Main Benefits

Grupo Antolin now has great visibility in the efficiencyof its Portuguese production lines. The critical data isused to analyse new ways to improve the process.In the words of Rui Araújo, Production DepartmentDirector at Grupo Antolin’s Lusitânea plant: “Thanksto the OEE system, we have managed to automaticallycompile data and automatically manage job orders, editinformation, analyse graphics and create reports that wedefine through a user interface.”

This document was realized thanks to the support of:Rui Araújo, Production Department Director, Grupo Antolin,André Brandão, Project Manager and João Caldeira, Automotive Technical Engineer,Sysmaker, Wonderware ArchestrA-certified system integrator.

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Automotive

Figure 2: History of machine use condition.

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Magna Automotivewww.magna.com

“Wonderware’s object basedtechnology, especially withthe new embedded graphicscapability, was a hugebenefit to the successfulcompletion of the project.”

Nigel King, Senior Software Consultant, SDI Group

Logistics boosted at Magna Automotiveby Wonderware United Kingdom

Goals: • Magna Automotive was required to increase the

number of panel variations to handle therequirements for both the outgoing and newvehicles, which meant an increase in the number ofvariances of around 17 per cent.

Challenges: • The project had to be completed in a very short

time;• There shouldn’t be any plant shutdown and

production had to be maintained while expansion isbeing undertaken;

• The new system must show improvement in quality,throughput and space utilization.

Wonderware Solution: • InTouch HMI;• Wonderware System Platform.

Results: • The ease of use of the operator screens required

minimal input. This enabled new personnel tooperate the plant with very little training;

• On-Time delivery;• Increased Productivity by an increase in available

workforce equating to a headcount re-deploymentof 8 per cent;

• Enhanced the Automation and Control System byimproving stock control, production planning, andinspection of stock produced, as well as addingadvanced, automated reporting capability.

17

Burton-on-Trent, United Kingdom - MagnaAutomotive is a major supplier of components tothe automobile industry. Faced with increasingdemand and the need to improve plant efficiencyand product quality, they have decided to re-vamptheir manufacturing facility in Burton-on-Trent, UK.This was a major task that had to be undertakenwithout any stop in production. Magna Automotiveselected the Wonderware System Platform becauseits capabilities provided the ideal solution to addressthe short project completion schedule and in-project continuous improvements.

Magna Automotive operates a manufacturing andproduction site at Barton Business Park in Burton-on-Trent. The facility is part of the company’sInteriors Division supplying injection mouldedinternal door panels to a nearby car manufacturer. Itprovides parts for two different vehicle models,working on a just-in-time inventory strategy with afour-hour notice period for incoming orders.

The Situation - Increasing Capacity withMinimum Cost

The plant manufactures door panels for two vehiclemodels but there are a number of differentvariations because of different interior options thatare offered to the consumer. A planned modelchange scheduled for the first half of 2008 hasnecessitated Magna Automotive to increase thenumber of panel variations to handle therequirements for both the outgoing and newvehicles. This meant a 17% increase in the number ofvariances. As a result, additional space was needed atthe Burton-on-Trent facility to accommodate theextra production equipment. Magna Automotive wanted to identify the mostcost-effective solution that met production needs.

Seeking at Solution

SDI Group UK was invited by Magna Automotive todesign the automated system for the storage andretrieval of the injection moulded interior car doorpanels manufactured at the production site. A turn-key solution was required to primarily optimise theexisting facility, freeing up valuable space for newequipment, whilst avoiding any disruption to theongoing operation.

The project’s scope also included enhancingworkforce productivity; maximising capacity forfuture business wins; and increasing operationalvisibility and control. The solution would have totake into consideration the unique needs of a just-in-time inventory strategy within the automotivesector, which demanded particularly high levels ofaccuracy, faster completion time and increasedproduct quality.

The Solution – an Improved Control SystemPowered by Wonderware

An essential aspect of the solution was asophisticated Warehouse Control System (WCS)installed with a Wonderware software solution. TheWCS has enhanced the overall control of themanufacturing plant and increased the ability tobetter manage the site. Wonderware software

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InTouch HMI, Wonderware System Platform.Automotive

Figure 1: Automobile components in motion.

provides overall control at each stage of theproduction process from manufacture of parts,through to storage and then transfer to productionareas and drop-off points. This comprehensive WCSnot only had to control the automated storage andretrieval system, but the entire life of each part frommanufacture and production to the point ofdispatch.

A key feature of the WCS is the easy-to-use touchscreen operator interface using InTouch HMI(Human Machine Interface). The operator screenswere designed for ease of use and minimal operatorinput. This means that new operators can beintroduced with very little training on the softwarerequired.

The software also offered greater control overstock, operating an effective FIFO (first in first out)parts usage system, as well as providing a completeaudit trail for every part within the facility. Theautomated solution utilised more than 3,500 sensorpoints providing useful stock data and enabling theability to monitor parts trolleys throughout theprocess. Data could be accessed and inputted viaoffice-based computers or five touch screenmonitors situated within the production facility. Each operator station can display a live animated

visualisation of the control equipment with pan andzoom functionality. This provides detailed diagnosticinformation to engineers and operators right on theplant floor. Detail of stock holdings by part and bylocation with ‘drill down’ comprehensive informationis available to the plant personnel. The details anddestination of all trolleys moving on the conveyorsystem are also displayed in real-time. A history ofthe trolley’s movement is available.

A remote Management PC also provides the sameequipment visualisation and stock information butwith additional features for supervisors. Thesefeatures include part definition creation /modification, part to storage lane allocation, usermanagement, problem recovery and softwareapplication status display. The WonderwareHistorian has enabled data to be stored and collatedfor reporting purposes, something that waspreviously processed manually.

The Core of the Solution – WonderwareSystem Platform

The Wonderware System Platform provides real-time automation supervision for the WCS(Warehouse Control System). Nigel King, Senior

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Figure 2: New mezzanine.

Software Consultant, SDI Group, “Wonderware objectbased technology, especially with the new embeddedgraphics capability, was a huge benefit to the successfulcompletion of the project.” Wonderware System Platform was designed withreal-world project experience in mind whereobjects can be designed and rigorously tested anddeployed repeatedly in multiple instances across theapplication. The WCS uses Wonderware SystemPlatform and six InTouch HMI nodes for visualisationand supervisory control.

The system’s natural connectivity takes care ofcommunications to automation controllers (mainlyBeckhoff PLCs) and external databases. TheWonderware Historian provides History and Trendinformation. When the production facility matures, itwill provide detailed insight into operationalperformance and provide useful information forcontinual improvement programmes.Although SDI Group is a long standing Wonderwareuser, Nigel added, “We needed confirmation of ourdecision making and approach with the new version ofWonderware System Platform, Wonderware UnitedKingdom support staff and consultants providedknowledgeable and helpful guidance in both the initiallearning curve and during the project’s execution.”

Return on Investment

SDI group delivered all of the requirements thatwere part of the project; these resulted in

measurable business benefits that ensured earlypayback of the investment: The materials handlingsolution took just 10 months to be designed,installed and become fully operational. The projectwas completed within the required schedule withzero operational downtime. Increased Productivityresulted by an increase in available workforceequating to a headcount redeployment of 8 percent.

Implementation

The installation was completed within the requiredtimeframe, so Magna Automotive has been able tomeet the delivery deadlines for new parts to itscustomer’s car production line. Zero downtime wasachieved during the course of the design and buildprocess, with no forced stoppages as a direct resultof the project; this ensured that Magna Automotivewas able to continue to serve its customer withoutdisruption throughout the course of the installation.

On-Going Benefit

Notwithstanding the 2009 economic situation,Magna Automotive now has a far more efficientproduction system which will provide businessbenefits long into the future. The utilisation of theWonderware System Platform will continue toprovide measurable cost savings in operation andwhen inevitable changes to production occur.

This document was realized thanks to the support of: Magna Automotive.

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Schaeffler KG www.schaeffler-group.com

“The extensive preparation work done by theteam in first understanding the requirementsand harsh nature of the environment, togetherwith the use of the most sensible toolsresulted in an excellent working solution,fulfilling our requirements completely.”

Gwilym Wilkins, IT manager, Schaeffler Automotive.

End-to-end batch mixing and tracking at Schaeffler’s PortElizabeth plantby Wonderware Southern Africa

Goals:• An automated warehouse inventory control

system;• A batch tracking system that would track raw

material batch numbers through to final productand vice versa;

• Reporting facility.

Challenges:• System to operate in adverse and dirty

conditions.

Wonderware Solution:• InTouch HMI;• Wonderware Manufacturing Execution Module;• Wonderware System Platform.

Results:• Automated process – Greatly reduced operator

error while providing the necessary guidance foroptimal smooth running of processes;

• Accurate warehouse management system; • Easier, more reliable operation; • Mixing benefits with strict recipe management and

scrap reduction;• Traceability – It is now possible to trace raw

material batch numbers from the suppliers to theend product and vice versa

• Reports – Using the company’s intranet, reportssuch as stock levels, batch tracking, raw materialtracking, batch details (e.g. weights per material)and exception errors such as process problems canbe viewed.

• Computer failure recovery.

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Port Elizabeth, South Africa - With its threestrong brands - INA, LuK and FAG - the SchaefflerGroup is involved in the automotive, industrial andaerospace industries and stands for a pronouncedcustomer focus, innovative power and the highestpossible product quality. In 2008, approximately66,000 employees at over 180 locations worldwideachieved sales totalling nearly 9 billion Euros. Thegroup belongs to the leading suppliers of the rollingbearings industry worldwide and is a valuablepartner of nearly all automobile manufacturers.

With the LuK brand, the Schaeffler Group is one ofthe world’s leading clutch and transmissioncomponent manufacturers. Today, one in four carsworldwide has a LuK clutch and customers includeseveral renowned automotive manufacturers.

Schaeffler’s Port Elizabeth manufacturing facilityconsists of a 15,000 m2 production area and 3700m2 warehouse all on a 36,000 m2 site with 450employees, 15 of whom are involved with researchand development and 27 in the tool room. Annualturnover is 40 million Euros and 2007 productionachieved 2.5 million facings and 1.1 million clutchsets. The plant has the capacity to produce 1.7million clutch sets and more than half its productionis targeted for export.

No matter how exotic the car, vehicles not using‘wet’ clutches (automatic transmission) rely on arelatively thin layer of special material to interfaceengine power with the driven wheels – the clutchfacing.

In order to live up to Schaeffler’s (LuK’s) exactingquality standards while meeting large demands, theproduction process of these facings at the

company’s Port Elizabeth facility needed to berevised to incorporate the latest batch mixing andtracking technologies in a difficult manufacturingenvironment.

Project Requirements

The business objectives called for an automatedwarehouse inventory control system, a batchtracking system and a reporting facility. Materialwould be picked according to its expiry date whileprovision would have to be made for stock levelsand the location of all stock to be readily available toqualified personnel.

The batch tracking system would need to track rawmaterial batch numbers through to final product andvice versa. There was also a need to interface to alaboratory testing facility.

While the need for reliable operation goes withoutsaying in a real-time production environment, theconditions at the plant proved to be somewhatchallenging with an atmosphere thick with carbonblack (figure 1).

To overcome this, a simple and robust operatorinterface was required as the standardkeyboard/mouse combination had proved uselessand even touch panels were prone to failure.

Solution Selection

Both the hardware and software needed upgradingand a fresh approach was necessary. “Since the existing SCADA facility was based onWonderware’s InTouch HMI (Human MachineInterface) and Wonderware Manufacturing ExecutionModule (previously known as Wonderware InTracksoftware) solutions which had served the company wellsince 1997, it made sense to continue using productsfrom the Wonderware stable,” says Barry Clemence,software engineer at DC Industrial Scanning, thesystem integrator chosen by LuK. DCI Scanningchose the Wonderware System Platform based onArchestrA technology as well as the WonderwareInformation Server.

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InTouch HMI, Wonderware Manufacturing Execution Module,Wonderware System Platform.

Automotive

Figure 1: Not the best environment for electronic equipment.

Solution Architecture

The system topology is shown in figure 2, whichalso illustrates the three-button operator interfaceand hand-held wireless computer.The buttons allow for easynavigation betweenscreens, function selection,SQL grid selection andexecuting the steppingsequence while being easilyreplaceable at very lowcost. The mouse andkeyboard are now onlyused for administratorfunctions. “The buttons areconnected to a standardserial port and a .NET objectwas written inside ArchestrAto do the interfacing,” saysClemence. “The result is arobust unit made fromreadily-available components.”

The hand-held wireless computer is used to guidethe operators via screen prompts while allowingthem to scan barcodes or key in information on themove throughout the plant. This was also integrateddirectly into Wonderware System Platform withanother .NET object. The new Wonderware SystemPlatform SQL object provided a reliable way tointerface to the SQL database. The new SQL Gridproved to be very flexible and was a great way todisplay database information.

“One place we used the gridwas to display the variousrecipes thereby enabling theoperator to select and start therequired recipe using thebutton interface,” addsClemence.

The Wonderware SystemPlatform application isinterfaced with LuK’s Oraclesystem to retrieve theinformation for the materialreceived and the system hadto be developed, tested andimplemented live. “We did dry

runs where possible,” says Clemence, “but withimplementation came the normal teething issues andspecification changes.”

Realised Benefits

• Automated process – The level of automationand checks and balances incorporated into thesystem has greatly reduced operator error whileproviding the necessary guidance for optimalsmooth running processes;• Accurate warehouse management system –This now provides current stock levels immediatelyon request and knows where each bag of material isstored and how much is left. This has led to lessmaterial loss due to material expiry;

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Automotive

Figure 2: System topology.

Figure 3: The pre-mix process.

• Easier, more reliable operation – Wirelessscanner and screen prompts as well as the robustbutton user interface allow operators to do a betterjob;• Mixing benefits – Strict recipe management nowprevents the wrong materials being added to the

mixture or added in thewrong amounts which allcontributes to reducingscrap;• Traceability – It isnow possible to traceraw material batchnumbers from thesuppliers to the endproduct and vice versa;• Reports – Using thecompany’s intranet,reports such as stocklevels, batch tracking, rawmaterial tracking, batchdetails (e.g. weights permaterial) and exceptionerrors such as processproblems can be viewed.The back end is

powered using a combination of Microsoft SQLReporting Services and Wonderware ReportingServices;• Computer failure recovery – It is now easyto recover from a computer failure whereas thiswasn’t previously possible.

This document was realised thanks to the support of:Gwilym Wilkins, Schaeffler Group, andBarry Clemence, DC Industrial Scanning.

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Automotive

Figure 3: Aerial view.

Industry: Chemicals, Agriculture

Bayer CropScience AG www.bayercropscience.fr

Wonderware and SITAM participate in increasing the planttreatment productivity with the FROGSS project (FungicideROtating Greenhouse Spraying System)by Wonderware France

Goals:• Increase treatment capacity with regards to the

Biology department;• Reduce biologists’ contact with the treated plants;• Implement a new organization within a maximum

of 18 months;• Provide operating tools that are easy to use.

Challenges:• Referral agent partners for each business involved

in the project;• BAYER / SITAM work group: a commitment for the

success of the project;• An open software environment.

Wonderware Solution:• ActiveFactory software;• InTouch HMI;• Wonderware Historian.

Results:• Comply with priorities and deadlines in

implementing and deploying the solution;• Cost of the solution controlled thanks to the

stringency of the SITAM management processes;• Quick familiarization;• Control and transparency of the information:

factors for successful collaboration.

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“The choice of Wonderware was in thisproject a major step and we can nowmeasure all of the flexibility that thishas provided us with in theimplementation of this robot.”

Martine ZUCCOManager, Robotics Team, Bayer Cropscience France

La Dargoire (Lyon), France - Bayer is aninternational group of which the core businesses fallwithin the health, nutrition and high-performancematerials sectors.

Bayer CropScience AG, a subsidiary of Bayer AG,with an annual sales figure of about 6.4 billion euro(2008), is a company leading the way in innovationworldwide in the fields of crop protection, non-agricultural pest management, seeds andplant biotechnologies.

The company offers an extensive rangeof complementary products andservices for modern andsustainable agriculture, aswell as solutions for non-agricultural applications.

Bayer CropScience hasinvested nearly 10 million euroat La Dargoire over the last twoyears in order to provide theexisting laboratories with state ofthe art equipment.

The Biology department hasbenefited from a part of thisinvestment in the creation of a new fully-robotized system for large-scale testing of theeffectiveness of new molecules on plant diseases.

The FROGSS (Fungicide ROtating GreenhouseSpraying System) project was born. Its functionalscope concerning the steering monitoring solutionremains to be defined.

The customer’s request was to obtain a tool thatwas able to change easily according to needsidentified during the course of the project withoutjeopardizing what already exists.Their choice was quickly orientated to aWonderware solution which offers a modular andopen architecture based on market standards.

The FROGSS project consists in automating:• the spraying of plant sets from a loading zone;• the drying for sprayed solutions in a drying tunnel;• the classification of plants by disease in trolleys;

• the washing and storing of the sets used in astorage zone;• the transporting of sets to the various zonesmentioned above;• the identification of treated sets and pots.

The sequencing of all of these treatments is called a‘Run’. This automation implements several elements:computers, automatic devices, conveyors, roboticarms, a LiquidHandler, trolleys, carts, doors, valves,cylinders, nozzles, elevators, lifts, shafts, motors,

pumps, cells, barcode readers, DataMatrixcode readers, etc.

In addition to automating the process,traceability is implemented throughout

the entire installation from takingthe set to arranging the pots,

including spraying.

The IT portion’sarchitecture is articulatedaround a Wonderwaresolution interfaced with thecustomer’s management

system (BCS).

The solution developed with theWonderware InTouch HMI

(Human Machine Interface) andWonderware Historian allows the followingfunctions to be provided:• Representation of the process structured in theform of block diagrams;• Real-time acquisition of process parameters;• Visualization of safety elements;• Acquisition of safety data;• Alarm management;• Recording and sorting of events or alarms forthose in the past or currently in progress;• Management of manufacturing programparameters;• Configuration for the ‘Run’;• Traceability management;• Exchanges with the BCS system.

“The management of alarms in the event of a default,their traceability and the facility for repair is a notableadvantage. In addition, the possibility via Wonderware to

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ActiveFactory software, InTouch HMI,Wonderware Historian.

Chemicals, Agriculture

secure the access by setting up different user levels wasa major criterion in our choice” states Martine Zucco,Manager, Robotics Team, Bayer CropScience France.

The InTouch HMI supervision interface wasdesigned in such a way as to provideoperators with optimal facility and user-friendliness in use.

A geographical representation of theequipment allows for a complete view ofthe monitored installation. Navigationguarantees access to the information with aminimum number of mouse clicks, eitherfrom the geographical location of theequipment, or via shortcut buttons or acontextual menu. The interface is configuredautomatically via user profiles, which allowseach person to retrieve their workingenvironment. “It is certain that the speed ofusers getting familiar with this new tool is

directly correlated with the excellent ergonomics of thedifferent HMI screens,” states a user at BayerCropScience.

This documents was realized thanks to the support of:Bayer CropScience.

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Chemicals, Agriculture

Figure 1: Precision seed drill.

Industry: Chemicals

sia Abrasives Industries www.sia-abrasives.com

“The automated managementof scheduling activities andonline information comingdirectly from plant floorfacilitates the coordinationwith other divisions.Response time to changes inscheduling has beensubstantially reduced.”

Thomas Brandes,Work Order Planning Department, sia Abrasive.

A Comprehensive Plant Solution for the Production of Coated Abrasivesby Wonderware Switzerland

Goals: • Paperless connection between production and

production management systems.

Challenges: • Outdated, inconsistent systems;• Local loss of data causing discontinuity and

frequent errors.

Wonderware Solution: • ActiveFactory software;• Development Studio;• Wonderware Historian;• Wonderware Information Server; • Wonderware Manufacturing Execution Module.

Results: • Unified dataflow;• Elimination of paper records;• Higher product quality and work simplification;• Faster reaction times thanks to the availability

of real-time data;• Better coordination between production

and other departments.

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Frauenfeld, Switzerland - sia Abrasives IndustriesAG at Frauenfeld (Switzerland) is one of the world‘sleading manufacturers of coated abrasives. Thecompany offers a product range of several thousanditems that are subject to continuous improvement.

sia Abrasives employs about 1.100 personsworldwide, 690 of which work in Frauenfeld. In2007, the business volume reached 298 million CHF,and great attention is being paid to the performanceand efficiency of the enterprise.

The Products: Coated Abrasives for VariousFields of Application

The coated abrasives produced at Frauenfeld aremade up of a carrier material such as paper, tissue,vulcanized fibre or plastic film. Through a continuousprocess, abrasive grains are applied to the backingand anchored by bonding adhesives. sia Abrasivesproducts are distributed worldwide and are used inmetalworking, woodworking, automotive bodywork,panel production et al.

Starting the Project

sia Abrasives produces coated abrasives on severalproduction lines based on specific products andeach consisting of a number of subordinate units.

Before the introduction of production management

system, there was no connection between thecontrols of the individual production units. Thus, theplanning of the various production processes andthe management of the machines’ setup were highlylaborious and inefficient. Moreover, manufacturingdata were administered via different, non-compatiblesystems which led to errors caused by mediaconversions.

As process data accumulated locally, great effortshad to be made for consistent quality controlbecause of the lack of a common database. siaAbrasives therefore decided to introduce anextensive automation solution that facilitatesproduction control and reporting.

After evaluating different options, sia Abrasivesdecided to entrust this challenge to Wonderwaresoftware and acs ag, a Wonderware systemintegrator from Wil / Switzerland. Theimplementation began in 2003 with the final goal ofcreating a paperless solution that connects the plantfloor to the production planning and control (PPC)system.

Developing a Comprehensive Plant Solution

All plant information is now stored centrallythrough a Wonderware Historian. Thanks to thishigh-performance real-time database, theinformation from the control system used forplanning and reporting are available to all work

stations based on the different roles andauthorization of the personnel.

The Manufacturing Execution Module andthe open interfaces provided byWonderware software enables thestandardization of data flow. The solutionenables production orders to be centrallydispatched via a PPC (production planningand control) work station.

At any time it is possible to check andsupervise the status of batches in thevarious process steps. Plant floor isconstantly updated with real-timeproduction order information.

ActiveFactory software, Development Studio, Historian,Information Server, Manufacturing Execution Module.

Chemicals

Figure I: A wide product range for various fields of application.

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The Results: a Secure and Open System

Thanks to the newly established connectionbetween control units and database, it is possible tomanage machine setup automatically. Since it is nolonger necessary to input data manually, theWonderware solution helped eliminate animportant source of errors. Thanks to the network connection, it is now

possible to comprehensivelyevaluate, analyze andsupervise several productionlines. It is also possible toeasily expand the system inconnection with theproduction scheduling andcontrol system (PPC): Due tothe use of state-of-the-arttechnologies and non-proprietary interfacesprovided by Wonderwaresoftware, further equipmentand applications can beintegrated with the existingsystem.

Success Thanks to SystemIntegrator

The Swiss company acs ag hasbeen successfully realizing

projects in automation and MES (ManufacturingExecution System) with Wonderware softwaresolutions for more than 15 years. Thanks to thisconsiderable experience, they were able to satisfycompletely the customer’s requests. An in-depthanalysis of the given situation, as well as the bestcombination and set-up of software components, ledto maximum benefit for the end customer.

This document was realized thanks to the support of: sia Abrasives Industries AG and acs ag, ArchestrA-certified system integrator.

ActiveFactory software, Development Studio, Historian,Information Server, Manufacturing Execution Module.

Chemicals

Figure 2: Each production line consists of a number of subordinate units.

Industry: Construction, General Process Manufacturing, Mining

DiGeronimo Aggregateswww.digeronimoaggregates.com

“Allowing local control ofequipment using thetablet computers andwireless network haseasily paid for itself insavings compared to thecost of running conduitand wire for localcontrol.”

Andy Holtom, Electrical Engineering DivisionLeader/Principal

Wonderware Software Brings Aggregate Plant Up to Date andEnhances Operationsby Wonderware

Goals:• Transition fuel system from oil/gas to coal;• Comply with EPA regulations and reporting

guidelines;• Improve product quality and consistency;• Expand plant and ensure future scalability.

Challenges:• Facility built in the 1800s, operating with outdated

electrical systems and equipment;• Plant is spread out over 65 acres;• Huge power requirements to operate kiln;• End-product uniformity dependent on consistent

kiln temperature.

Wonderware Solution:• ActiveFactory software;• InTouch HMI; • Wonderware Industrial Computers (InTouch HMI

embedded);• Wonderware System Platform.

Results:• Energy and time savings through Wonderware-

enabled proactive maintenance of kiln and otherequipment;

• Ability to plan and schedule maintenance bringscost savings of $5,000 each time a pre-heat/re-heatof the kiln is avoided, resulting in total savings ofover $100,000;

• Remote monitoring added for improved visibilityand management of overall operation;

• Operators more efficient due to at-a-glance abilityto assess plant conditions;

• Scalability and standardization ensure quick andeasy equipment additions and expansion.

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Independence, Ohio – Just a couple of years ago,a time traveler from the 1800s visiting theDiGeronimo Aggregates plant would have been infamiliar surroundings. The operation was burning gasand oil and operating as it had for the last 150 years– crushing raw shale and bringing it to the kilnwhere it is heated, then cooled, ground and graded.The process yields a versatile end product that isused for high-performance, lightweight structuralconcrete and masonry, professional turf,horticultural applications and geotechnical fills.

But the plant’s new owners had a more modernvision and aspirations to improve productivity andproduct quality while planning for future expansion.They set about transitioning the facility to coal fuel,upgrading the electrical system and other equipmentto better meet EPA regulatory requirements, andimproving the overall efficiency of the enterprise.

Managing a Multifaceted Project

The management team at DiGeronimo Aggregateswanted to implement the new system in the mostcost-effective and timely manner, so they decided tosupervise the project internally, enlisting a numberof key partners to assist. Wonderware Cincinnati,the regional Wonderware distributor workingclosely with the management team recommendedHull & Associates, Inc. a Wonderware ArchestrA-certified system integrator with experience inelectrical engineering and control systemsautomation.

DiGeronimo agreed with the selection of Hull &Associates, Inc. because they could providestandardization through the Wonderware softwaresolution that would enable coordination of the manysuppliers, which was vital to the teamwork andultimate success of the complex implementation.

Besides the economic advantages of switching fromoil to coal, the initial analysis uncovered anopportunity to design and deploy a centralizedmanufacturing automation solution incorporatingprogrammable logic controllers (PLCs), supervisorycontrol and data acquisition (SCADA) capabilities,and a human machine interface (HMI). The resultingsystem was projected to decrease energy use anddeliver operational cost savings as well as a higherquality, more consistent product.

Challenges for Operators and Management

Because of the age of the plant and its 65-acre size,operators faced a number of impediments. Theirprimary means of monitoring the kiln was visual; ifthe size of the flame seemed steady, thetemperature should be in an acceptable range.

More accurate, real-time data was not available andconduit running between the numerous stations wasused for wired communications. Operators had totravel to remote stations to determine whetherthey were functioning properly and to record andreport data.

Additionally, the plant management office was acrosstown, so executives did not have the ready access tocurrent performance data that they needed forinformed decision making.

The Kiln is the Key Component

The centerpiece of DiGeronimo Aggregates is thekiln, which heats the crushed shale, altering itscellular structure to form a material which is light,yet extremely strong and durable. To produce consistent product batch after batch,the kiln temperature must remain as stable aspossible at around 2,200 degrees Fahrenheit.

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ActiveFactory software, InTouch HMI, Wonderware IndustrialComputers (InTouch HMI embedded), Wonderware System Platform.

Construction, General ProcessManufacturing, Mining

Figure 1: DiGeronimo Aggregates HMI screen.

Saving Energy Means Saving Money

Energy consumption is a major concern for theplant because the kiln operates 24/7 to produce upto 700 tons of product each day. Maintenance iscritical, because unplanned shutdowns are extremelycostly. Returning the equipment to its very highoperating temperature requires a large amount offuel and takes time, lowering productivity.

Conversely, the ability to plan kiln maintenance cansave energy and money while maximizing output.Now, with Wonderware software, sensors in the kilnalert operators to changes that might indicate theneed for a future repair. And the system enablesmanagement to schedule required maintenance.

Eric Dombrowski, Vice President for DiGeronimoAggregates, puts it into perspective, “It costs about$5,000 for each pre-heat or re-heat of the kiln. Sincegoing online with Wonderware, we’ve been able to planfor maintenance, rather than having forced shutdowns,which has helped out tremendously.”

Consistency is Crucial for Quality

Because different fuel sources burn at differenttemperatures – and because temperature has asignificant affect on the quality of DiGeronimo’sproduct – the switch to coal had to be madecarefully. The Wonderware solution gavemanagement and operators the ability to setbenchmarks and make needed adjustments duringthe transition so the new system was runningconsistently in a short time. PLCs provide feedbackthat helps prolong the life of equipment bymonitoring corrosion, which can be caused bytemperature fluctuations.

Complying with Strict EPA Requirements

DiGeronimo Aggregates is subject to stringentEnvironmental Protection Agency (EPA) Title Vregulations. The plant is required to report daily,monthly, peak and low average measurements fordust emissions, lime injection statistics and coal-feedrates.

In the past, these records were kept manually, and itwas time-consuming and slow to compile the EPA-required reports. But with the addition ofWonderware Historian software, collected data isnow downloaded, processed and charted forsubmission quickly and easily.

For out-of-compliance events, the Wonderwaresolution shows on-screen alarms, plus it enablesoperators to generate reports to show how quicklycorrective actions were implemented andoperations returned to compliance.

Improved Efficiency Through RemoteMonitoring and Real-time Data

Another benefit of the Wonderware solution is thatits central control station has improved operatorproductivity. In the past, operators had to travelaround the large DiGeronimo campus to inspecteach motor station. Now, with the central stationand remote monitoring capability, operators havereal-time information on which stations needattention, and they can make most correctionswithout having to visit the actual equipment.

Additionally, Wonderware Industrial ComputersInTouch HMI embedded) and a wireless networkhave been deployed, so when an operator isrequired to go to the site of a motor, bearing ortemperature element, the operator can view theWonderware screens on the tablet and makeadjustments immediately in the field.

Operator communications abilities have alsoimproved with new docking stations in eachelectrical room and radios. Cameras display criticalequipment and conveyor belts to provide visualverification of operations. All of these capabilitieshelp DiGeronimo remain as productive as possibleand head off problems before they happen.

The Wonderware solution’s remote access has alsohelped Hull & Associates, Inc. serve DiGeronimobetter when it comes to remote configuration,continued development and maintenance. Eventhough the integrator is over 100 miles from theplant, changes can be made over VPN immediately.

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Ease of Use and Standardization

With the Wonderware solution, all of thesecapabilities have come together to form astandardized system that has been well-received byDiGeronimo’s operators and managers.

Dombrowski says, “We were able to identify criticalvalues and ask Hull & Associates, Inc. to customize ourscreens very quickly.” New equipment can be addedsimply and easily and operators are already familiarwith the corresponding on-screen objects andcommands. They can see the entire plant in oneglance and make immediate judgments, rather thanhaving to generate and then interpret spreadsheets.

A Modernized System with Scalability for theFuture

So if that same time traveler visited DiGeronimoAggregates today, they would be impressed with theoperation’s 21st Century capabilities. Operatorscould explain how much more efficient they are,since they can view the entire plant on screen and

do much of their jobs from the central station. Theycould report on their increased ability to proactivelyrepair equipment and avoid unexpected and costlyshutdowns. And management could talk about howbetter real-time and historical reporting is enablingthem to make better decisions for the profitabilityof the enterprise.

Just as importantly, Wonderware software hasprovided DiGeronimo Aggregates the flexibility tomeet the needs of the current transition as well asto plan for expansion. Hull & Associates, Inc. installeda limited number of servers during the initialdevelopment and deployment. In the future, they willbe able to help DiGeronimo scale up by addingservers and more licenses, but without the need toinvest in a lot of additional development time andhardware.

Some might even say that – with help fromWonderware – DiGeronimo Aggregates is takingadvantage of the best of both worlds: 150 years ofheritage and experience along with the mostadvanced manufacturing operations managementsystems of today.

This document was realized thanks to the support of: Wonderware Cincinnati.

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Industry: Facility Management

Logitek, S.A.www.logitek.es

Logitek opts for domotics in its main office building andpromotes energy savings with Wonderware technologyby Wonderware Spain

Goals: • Control the building’s installations;• Remote control;• Save energy.

Challenges: • The integration of different technologies (light, air

conditioning, domotics, security...) in only oneapplication;

• To avoid different kind of local manual control;• To make all the facilities’ systems working in

concert in order to obtain the best environment.

Wonderware Solution: • ActiveFactory software;• InTouch HMI for Terminal Services; • Wonderware System Platform.

Results: • Integration of the company’s domotic services with

access from various stations via a clear, attractiveinterface;

• Direct access to installation data (temperature,consumption), thus helping to reduce energy costs;

• Availability of a platform in which any new buildingdevice can be integrated;

• Energy saving.

35

“Thanks to the installation of the Wonderware SystemPlatform in our offices, we now have a platform inwhich we have been able to integrate all the domoticfeatures of the building as the need arises. Its openarchitecture does not impose limits on the inclusionof new functions.”

Fernando Conde,Application Consultant, Logitek

Rubí (Barcelona), Spain - Thanks to theinstallation of the Wonderware System Platform andB&R technology, Logitek has managed to integrateall the domotic features of its building into its mainoffices (located in Rubí, Barcelona), with thepossibility of incorporating new functions as theneed arises. From the control of lighting and blindsto air-conditioning and the library’s projectionscreen, its open architecture does not impose limits,helping to create a work environment that is moreaccessible, safe and respectful of natural resources.

Towards an Intelligent Headquarters

Logitek is a leader in providing process automationsolutions that allow industrial companies to makeintelligent real-time decisions. In November 2008, Logitek centralised its variouscorporate departments into one same building. Thiscoincided with the move to its new main offices inRubí (Barcelona).As a company that is always at the vanguard oftechnologies, Logitek wanted to implement a systemthat would save energy in its facility. This is keepingin line with the company’s philosophy of respectingthe environment and promoting sustainability. Fromthis need arose the requirement to automate thedifferent domotic systems of its main office (air-conditioning, lighting and control of blinds) anddesign an intelligent building with the capacity ofintegrating new functions as the need arises.Logitek decided to implement an application basedon Wonderware System Platform to integrate thedomotic systems and monitor energy resources.

Because of this, Logitek was able to achieve its threemain aims: to optimise energy consumption (bymodulating water, air-conditioning and lightconsumption), to improve building safety (withgreater control over alarms and security cameras)and to make available reports and statistics usingcollected data.

An Integrated Environment

As Fernando Conde, Logitek Applicant Consultant,explains: “The aim is to control the building’s variousinstallations, integrating the hardware and protocols ofdifferent systems into one environment.”

The platform is based on Windows 2003 that acts asan object server, communications controller,Wonderware Historian and InTouch HMI (HumanMachine Interface) for Terminal Services.The Wonderware solution is comprised of: • Wonderware System Platform that provides aunique platform for all automation needs;• InTouch HMI for Terminal Services, software forprocess visualisation and control;• Wonderware Historian, real-time historian;• ActiveFactory software, a complete series of highlyflexible tools to access to visualise and analyse data.

Complete Environmental Control

The installation was fully carried out by CognicaseManagement Consulting, a Wonderware systemintegrator that has great experience in domoticapplications. The following functions were initiallydeveloped through the Wonderware ApplicationServer which is part of Wonderware SystemPlatform solution and InTouch HMI View:• Changes to air-conditioning orders; • Monitoring of, and manually forced, lighting in themain office and monthly programming turn on/offlighting according to sunlight conditions; • Programming the rolling up and down of blinds inaccordance with specific times and sunlightconditions; human presence and facade orientation;• Control different scenario in the Meeting Room.Intuitive handling was an important designconsideration because of the high number of usersaccessing the control of the InTouch HMI screens.

36

ActiveFactory software, InTouch HMI for Terminal Services,Wonderware System Platform.

Facility Management

Figure 1: Office synopsis showing the temperature level controlled byWonderware System Platform.

Large buttons were used with few keyboard entriesin order to optimise the use of the touchscreens.Once the installation had been activated, a checkwas made to see if the installed infrastructure couldserve as a basis for other elements and functionsthat were not initially planned.Fernando Conde explains: “These elements weregradually integrated in accordance with our needs. Oneexample is the security cameras positioned at theentrance to the offices: using the InTouch HMI softwaresolution, we’ve made it possible for it to change directionso the most suitable video can be viewed.”

Similarly, thanks to the cable structure of the offices,the cameras are connected to the local network viaTCP/IP and included in the touch control of theInTouch HMI application.

This complete control capacity also extends to theelectricity consumption and environmental temperaturecontrol. Consequently, “by using the peripherals distributedby B&R, measurement can be made of the total electrical air-conditioning consumption,” adds Conde.

The air-conditioning parameters used intemperature control are stored by the WonderwareHistorian, “has helped to optimise the operation timesof the air-conditioning.” Major energy savings wereachieved thanks to this and it truly had an economicimpact.

The Wonderware solution also helps to control variousdifferent scenarios. For instance, with one single key, thesystem controls lighting, blinds, the projection screenand adapts the room to different uses.

Main Benefits

The implementation of a shared platform based onthe Wonderware System Platform, combined withthe peripherals distributed by B&R has helped tointegrate all the domotic features of the building. Full system access and control using easy-to-use andclear interfaces has also facilitated the acceptance ofthe system by all personnel.Similarly, its openarchitecture does not impose limits when it comesto adding new functions. This provides the possibilityof integrating new devices into the building easily.

“The projects already exist to integrate automaticgarden watering, access control into the offices and theanti-theft alarm into the same application,” points outConde.

The publication of different information (and someapplication screens) is also implemented in aWonderware Information Server portal. TheWonderware Information Server on that helps toadd and present performance and production dataobtained via the Internet or Intranet. By using theWonderware Information Server, it is possible toadd large quantities of process data in productionreports.

Fernando Conde concludes: “Direct access to datarelating to the installation, regulation and efficient controlof air-conditioning, lighting and water consumptiontranslates into an huge reduction of energy costs, thushelping to create not only ideal room temperature forthe staff, but also showing how to become more mindfulof limited natural resources. We save more than 5%energy due to the reduction of the electricityconsumption, when people are not at the office and alsobecause the automatic disconnection of all the electricalappliances when the alarm turns on.”

The benefits of domotic applications are beingstrongly incorporated into the day-to-day activitiesof companies, helping to create greater comfort,safety and ease that promote a much moreagreeable, healthy and sustainable workenvironment.

This document was realized thanks to the support:Logitek and Cognicase Management Consulting, Wonderware systemintegrator.

37

ActiveFactory software, InTouch HMI for Terminal Services,Wonderware System Platform.

Facility Management

Figure 2: General view with all lighting system, air conditioning andshutters.

To an open, energy-savingFacility Management Solution

www.wonderware.com/fms

Make the Switch

Facility managers, building owners and end-users now have a competitive choice with open and flexiblesoftware from Wonderware. Our open Facilities Management Solution and network of independent systemintegrators can help reduce your total cost of ownership for installation, maintenance and service of applications.Lower energy costs and improve the security and performance of your workforceregardless of which building automation system you’ve installed. Ask for our FREE White Paper on how the Wonderware Facilities Management Solution canrelease you from costly proprietary systems. www.wonderware.com/fms

©2008 Invensys Systems, Inc. All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners.

WNDR-784 FacilityMan-ASHRAE.qxd:WNDR-ASHRAE.qxd 22-01-2009 11:40 Pagina 1


National Security Technologies, LLCwww.nstec.com

“We have a very stringent preventativemaintenance program. The summer monthsare tough. If a piece of equipment breaks,I know it immediately.”

Mark Lowell FroehlichSenior Operations Specialist/Automation Department of Energy NSTec

Nevada’s First Government-Owned Green Building UsesWonderware Software for Consistent Environmental Controlby Wonderware

Goals:• Reduce energy consumption and increase

conservation, including decreasing the facility’sdependency on oil;

• Comply with Energy Policy Act of 2005 and DOEOrder 430.2b, including extensive reportingrequirements for electricity and water use;

• Comply with ABSI/ASHRAE Standard 135/2004(BACnet) for interoperability.

Challenges:• Nearly 20 year-old Building Automation System was

not interoperable with other systems, makingcontrol and compliance very difficult;

• NSTec planned to perform all integration in-house,so ease of implementation was needed;

• Demanding desert environment and high summertemperatures required enhanced preventativemaintenance capabilities.

Wonderware Solution: • ActiveFactory software;• InTouch HMI; • Wonderware System Platform.

Results:• Reduced costs due to improved ability to manage

energy use during peak demand periods;• Better communications and integration of systems

by replacing the old, drum-based control systemwith a state-of-the-art, object-oriented system;

• More flexibility, centralized control and the abilityto make changes and upgrades quickly throughserver virtualization;

• A more customized system, including templates tofacilitated accelerated expansion.

39

Las Vegas, Nevada – When most people think ofLas Vegas, they imagine the intense heat of thedesert, the bright lights of the Strip, and the clang ofslot machines. With the immense amounts ofelectricity it takes to entertain visitors and keepthem comfortable, the city is not one you wouldimmediately associate with conservation.

But an important government agency based there isat the forefront. The Department of Energy NationalNuclear Security Administration’s North Las Vegasfacilities include Nevada’s first government-ownedbuilding to earn green status.

This goal was met with the help of National SecurityTechnologies, LLC (NSTec). Team NSTec managesthe operations of the North Las Vegas facilitiescomplex, where experiments that are vital to thenation’s security are overseen.

The company maintains these buildings inaccordance with the Energy Policy Act of 2005 andDOE Order 430.2b – regulations which provideincentives and mandate control of vital powersystems such as electricity and water.

The ultimate objective of these regulations isreduced energy consumption and increasedconservation, resulting in decreased dependency onoil. And federal agencies are required to lead byexample in compliance and validation.

Additionally, NSTec helps the facility achieve costreductions by managing energy use during peakdemand periods.

Strict Requirements for Control andValidation

To accomplish the goals of conserving energy,observing regulations for compliance, and savingmoney, NSTec requires the highest possible controlof the campus. The diverse environment must meetestablished standards for climate, air quality, lighting,and all other critical building systems.

Reports and records must show that thesestandards are being met continuously. Additionally,

the facilities have to comply with ANSI/ASHRAEStandard 135-2004 (BACnet), the internationalprotocol that ensures interoperability and futureflexibility as the operation’s building automationsystem grows.

This is no small task, considering that the North LasVegas facilities’ 18-year-old Building AutomationSystem functioned in standalone mode without agraphical user interface or real-time visibility formanagement of electrical, lighting, HVAC and otherkey systems. It lacked a common platform forintegrating equipment monitoring, energy efficiencymanagement, alarms and trending that would benecessary for control and compliance.

Two and a half years ago, Team NSTec decided toexplore opportunities to evolve the existing systemsto meet current and future needs. Any new solutionwould have to regulate the facilities, of course, but itwould also have to provide a more strategicapproach for critical equipment and systemsmanagement. The team partnered with authorizeddistributor Wonderware West to plan andimplement the project.

The Right Elements to Fit the Requirements

Team NSTec was looking for a number of importantcapabilities that would meet the needs of the mainbuilding now as well as the other areas of thecomplex in the future.

First, a stable backbone for managing the strategicfunctions that comprise the new system wasessential. The solution would need to be .NETcompliant and based on the Microsoft® platform forcompatibility with existing systems.

Ease of implementation was a necessity, as TeamNSTec hoped to perform all of the integration in-house.

Then there was the desire for an advanced graphicaluser interface that would map the completeoperation. Team NSTec wanted a visualrepresentation that would be flexible, intuitive to

40

ActiveFactory software, InTouch HMI, Wonderware System Platform.

Facility Management

use, and that would help staff and management ‘see’the entire campus. Multiple scripting would be a plusfor customization and speedy implementation ofchanges.

For Team NSTec, preventative maintenance isessential because of the desert environment,especially in the summer. A solution was needed thatcould provide real-time monitoring and trendingcapabilities that would fit the facility’s requirements.The new solution required tools to enable plantworkers to troubleshoot disruptions, study potentialoperational inefficiencies and eliminate the time-consuming process of locating data.

Finally, Team NSTec wanted the new system toautomatically identify possible problems and alertthe staff when established thresholds were breachedso that corrections could be made rapidly. And itwould need to provide all of the reports necessaryto track performance and keep the facility withincompliance.

After evaluation, Team NSTec decided that theWonderware solution was the right choice.

Implementation and Future Plans

With the new solution in place, Team NSTec quicklybegan to see the benefits that corresponded to theirspecific requirements.

First, the Wonderware solution updated theantiquated drum-based control system. With thenew state-of-the-art, object-oriented system, theTeam got the improved communications andintegration it was looking for. The new solutionenables the use of efficiently controlled systems andcritical equipment such as power meters across theentire facility.

Due to Wonderware software’s exceptionalscalability, the entire building automation system forthe North Las Vegas facilities complex is globallymanaged from NSTec’s central station. The team cantrend the equipment performance and monitor theenergy that it consumes. Along with equipmenthealth monitoring, they also can see its overall

performance, and the Wonderware solution enablescontrol of data centers, generator sets, substations,transfer switches and phone switches.

Another significant benefit – server virtualization –brings added flexibility for management. Now thatthe servers are virtualized, preparations forintegration into a server farm are in the forefront,allowing Team NSTec to control and operate thesystems from wherever they are, even outside of themain control room. Additionally, virtualization meansthat NSTec can maximize server resources andswiftly deploy changes and upgrades.

Dependability and compatibility are also improved.Because it is built on the .NET architecture, TeamNSTec can easily integrate Wonderware softwarewith other systems.

Team NSTec agrees that Wonderware Software’smultiple scripting capability is its best feature. Theability to easily create objects and symbols and todefine attributes means that the system is highlycustomizable. And its templates facilitate acceleratedexpansion and implementation of changes.

The Wonderware solution also supports preventivemaintenance requirements. If there are problems,the central station receives notification, andprioritized pager and mobile phone messages arealso sent to staff working elsewhere. This ensuresthat emergencies and faults are addressed accordingto severity.

Best of all, real-time reporting, trending andhistorical reports are easy to access and use. Thisrequires little or no training for the staff. It alsoensures that the facility is consistently controlled,and it stays in compliance, which is the #1 goal forTeam NSTec. To take these capabilities even further,Wonderware software would permit Team NSTec todevelop a system to perform demand-sidemanagement, a key element in achieving greenbuilding recognition and remaining within regulatorycompliance.

The Wonderware software solution will enable theteam to monitor and control the facility’s systems todecrease electrical energy use during peak periods.

41


Facility Management

To do this, the company will employ manytechniques, including raising set points in the buildingand locking out second-stage compressors or otherlower-priority equipment. Rolling outages will enableload-shedding and temperatures will be strategicallycontrolled by cooling the building prior to peakperiods so that lower temperatures are experiencedduring the heat of the day without excessive energyuse.

A Higher Purpose

With the combination of Team NSTec and theWonderware software solution, the complex hasbecome a leader in facilities management systeminitiatives.

By achieving compliance with the rigorous standardsof the Energy Policy Act of 2005 and DOE Order

430.2b, Team NSTec and Wonderware have helpedthe North Las Vegas facilities become a model forenvironmental best practices and green initiatives. In fact, it is anticipated that one day many morepublic- and private-sector buildings nationwide willstandardize the design of their systems based on theWonderware solution as implemented by TeamNSTec.

But even with all of this progress, the team breakstheir efforts down to a more basic level. MarkFroehlich says, “The DOE expects us to set the examplefor energy efficiency and share our knowledge with thecommunity. We have to be the shining star, and there’s agrave need for us to do so. As our population increases,our natural resources are lessening, and we have tomake some changes. We’re taking little steps andimproving our world.”

And Wonderware is pleased to help!

This document was realized thanks to the support of: National Security Technologies.

42


Power, Energy, General ProcessManufacturing


The Venetian Resort Hotelwww.venetian.com

“(The Wonderware solution) is a lifesaver. I can’t see not having it.”

Jerry Jaggers,Senior Project Manager, The Venetian Hotel Resort Casinos

World’s Largest Resort Relies on Wonderware Solution for Non-Stop Powerby Wonderware

Goals:• Provide uninterrupted power to the entire resort

complex;• Maximize the efficiency of widespread equipment

and workforce;• Enable flexibility and adaptability to accommodate

rapid growth.

Challenges:• Biggest hotel and resort in the world covering 67

acres and 14 million square feet;• 66 substations, 62 PLCs and staff are spread out

over a large area; • Any disruption of power can result in loss of

clientele and revenue.

Wonderware Solution:• ActiveFactory software;• InTouch HMI; • Wonderware Historian.

Results:• Power management and redundancy capabilities

ensure uninterrupted power 24/7/365;• Real-time monitoring enables proactive trouble

shooting and fixes;• Central monitoring of remote substations saves

staff time, resulting in bottom line savings;• Reporting and record-keeping capabilities support

rapid planning for expansion;• Wonderware solution supports green and

sustainability goals.

43

Las Vegas, Nevada – When visitors come to LasVegas, they may expect a few surprises in the casinosor enjoy an unexpected moment of amazementduring a show. But they definitely do not imaginethat their lavish vacation will be disrupted in any way– especially by interruptions in electrical power. Behind the scenes, complicated systems anddedicated teams work tirelessly to ensure thateveryone has a fabulous experience.

One of the brightest stars on the Strip is TheVenetian Resort Hotel family of properties. WithThe Venetian, The Venezia Tower, the Sands ExpoConvention Center and The Palazzo Las Vegas, these

properties comprise the largest hotel and resort inthe world, covering 67 acres and approximately 14million square feet of facilities.

And so it comes as no surprise that the complex hasone of the most innovative redundant power andFacility Management Systems ever developed. Part ofthe resort, The Palazzo Las Vegas, has been awardeda Silver LEED® Certificate (Leadership in Energyand Environmental Design) by the U. S. GreenBuilding Council. According to the Council, ThePalazzo is not only the largest green building inexistence, but is over four times bigger than thesecond-largest recipient of the designation. A commitment to green and sustainable processescan be seen throughout the resort.

A Team Focus on GrowthManaging the growth of The Venetian has been amajor task. Since its beginning in 1999, the otherproperties have been built or incorporated at a veryfast pace. Distributor Wonderware West andsystem integrator Electrical Systems Consultants(ESC) have collaborated with The Venetian’s expertsto create a facilities and power managementsoftware solution to provide real-time statusmonitoring as well as to support the other criticalneeds of the resort. President of ESC, Kevin Hartig,describes the effort, “In Las Vegas, things operate atwarp speed, and The Venetian’s no exception. They addedone tower after another, so we’ve had to respond very

quickly with expansionsto the system.Wonderware has allowedus to do that costeffectively and quickly.”For instance, the initialsystem was based onWonderware In TouchHMI (Human MachineInterface), whichprovides an easy-to-use, intuitive view ofthe resort. Then ESCassisted with theaddition of theWonderware Historianto expand real-timeand historical datacollection and

reporting capabilities. And future plans have beenmapped to other Wonderware components that canbe smoothly integrated when the time is right.According to Jerry Jaggers, The Venetian’s SeniorProject Manager, “when we added The Venezia, themain reporting of Wonderware saved us. We actuallytook the reports to see where we could add power to theother buildings and to see the usage. Then when we builtThe Palazzo, we used it to see how much more powerwe could use and where we can save it.”

Redundancy Enhances Guest Experiencesand Protects Revenue

In Las Vegas, normal takes on a whole new meaning.

44


Facility Management

And this applies to The Venetian’s power capabilitiesas well. The resort requires a predictable supply ofpower around the clock to fulfill its promise of aword-class guest experience.

The advanced redundant power system is fed with138,000 volts of electricity that come directly intothe complex from NV Energy, the region’s powersupplier. The power is broken down through twotransformers and distributed to the 66 substationsthat serve the vast property. All substations aredouble-ended and work in conjunction with 62PLCs which constantly monitor the flow ofelectricity. If one of the transformers is not sendingpower, the PLCs communicate thisinformation through theWonderware software. Such a faultwould trigger the substations toreact and pull power from the othertransformer to minimize fluctuationsand eliminate downtime. Thesoftware also works through thePLCs to perform real-time loadshedding to adjust generatorcapacities. Plus, Wonderwaresoftware also monitors standbygenerators that are available tosupply electricity to high-prioritysystems in the event of a completeloss of power.

The redundancy system and its sophisticatedmanagement capabilities are critical to The Venetian.It’s imperative that guests enjoy continuous electricityto power their Venetian experience – because in sucha competitive environment, any inconvenience forguests can mean lost business. An extended loss ofpower can mean billions of dollars in lost revenue forthe resort.

Real-Time Monitoring Brings Ease of Use andEfficiencies

The Wonderware solution’s real-time statusmonitoring capabilities enhance The Venetian’s abilityto meet the very high expectations of their visitors.With the system, facilities managers can view power

usage at every substation on the property. The statusof all equipment is visible on screen. Faults and alarmsappear as they happen in an easy-to-read graphicformat.

This increased level of visibility has brought dramaticgains in efficiency for the enormous campus. In manycases, operators can make corrections at a centralstation, eliminating time-consuming trips to remotelocations. And even when personnel do need to goto a site, they know exactly what they are lookingfor, so issues are resolved more quickly. This savestime as well as costs. Dale Mitchell, ElectricalSupervisor, explains, “Wonderware has improved our

efficiency to stay on top ofmaintenance. We go in and look atthe gear online, and we’ve spottedproblems before they’ve arisen. Sowe’ve had a chance to rectify thoseproblems before we haddowntime.” In the event of anemergency, the Wonderwaresoftware can speed up response.While members of the team aremonitoring an alarm event at thestation, others can be dispatchedto the location of concern. Andthe central team can be inconstant contact to communicatecurrent conditions and provideadditional information to

minimize power problems.

Supporting Sustainability and Success

By enabling proactive management of The Venetian’spower and providing ways to maximize staff for timeand cost savings, the Wonderware software fitsnicely with the resort’s focus on green andsustainability goals. The solution has been entrustedwith delivering superior capabilities, ease of use andreliability to The Venetian’s management and staff.And they, in turn, are responsible for providing anenjoyable experience to guests and visitors. It’s apartnership that is paying off handsomely for todayand for the future.

This document was realized thanks to the support of: Wonderware West and ESC Engineering.

45


Facility Management

Accelerate performance. Right out of the box. Introducing Wonderware Industry Application for Packaging.

Consistent performance coordination–that’s what’s missing! Packaging machine diversity and isolation ishindering fast and accurate production and process information. You need to get your products to marketfaster–and with higher profitability, efficiency and throughput. Wonderware Industry Application forPackaging software can help tie together your diverse set of packaging lineequipment and give you greater visibility to your operations. Ask for ourFREE White Paper on how the Wonderware Industry Application forPackaging can optimize your packaging operations–right out of the box.

www.wonderware.com/packaging©2009 Invensys Systems, Inc. All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners.

Something missing from yourpackaging operation?

ww_AD_Industry Application for Packaging 1 9-04-2009 16:07:39

Industry: Food & Beverage

Amadori Group, GESCO Consorzio Cooperativowww.amadori.it

The Ideal Temperatureby Wonderware Italy

Goals:• Optimize temperature management during the

meat processing steps;• Ensure traceability, with exact temperature data for

every step: processing, stocking and preservation;• Deploy a system that improves plant efficiency.

Challenges:• Difficulty in software migration from an outdated

version to a highly innovative and scalable system;• Create a temperature control system that adjusts

according to the external weather conditions.

Wonderware Solution:• ActiveFactory software;• InTouch HMI;• Wonderware Historian.

Results:• The Wonderware solution enabled the compliance

with government regulations;• The new system optimized production cycle and

energy management;• The automation of the production cycle helped

eliminating manual data entry errors;• The scalability of the solution, initially only

implemented in limited departments, has beensubsequently painlessly deployed in all the otherprocesses.

47

“In recent years, Amadori has always been asking for the mostinnovative solutions, aware that technological innovation allows usto remain competitive on the market. And this goal has led us tothe deployment of Wonderware solutions.”

Carlo Caramanico,Software Support, Cid Engineering

Teramo, Italy - Amadori is one of the marketleaders in the food processing industry. Founded inSan Vittore di Cesena forty years ago, the Group –with a turnover of over 1 billion euro in 2008 –leads the Italian market with 16 industrial plants and33 subsidiaries. It employs 6400 people. Amadorihas been successful because of its innovation anddecision to manage the whole production cycledirectly, allowing immediate control over everyproduction step. This includes choice of rawmaterials, farms, hatcheries, feed mills, processingplants, packaging and distribution.Tradition and innovation are the Group’s hallmarks:it is comprised of a professional team that presentsinnovative gastronomic solutions and works todeliver fresh and safe products to consumers.In the processing plant in Teramo, where breadedproducts and the ‘Il Campese’ line are produced, fulltemperature control is essential to ensure highproduct quality. The popularity of the AmadoriGroup has increased exceedingly in the past fewyears, thanks to advertisements featuring companytestimonials and the ‘guaranteed by FrancescoAmadori’ slogan. By emphasizing the high quality ofits poultry products in various versions, thecompany is sending out a strong and importantmessage.

The Ideal Temperature

One of the most important challenges facingindustrial plants is guaranteeing a consistently highquality level.

The most sensitive part of production is the correctmanagement of temperature, both in the processingand in the stocking and preservation steps.Temperature must be kept constant in the coldstores used in the preservation of slaughtered meat,to prevent it from quickly getting spoiled.It is important to avoid guesswork in thetemperature settings during the processing steps:every department is constantly monitored toprevent the modification of temperature metrics.A high temperature, for example, could favormicroorganism growth, risking to affect productquality. On the other hand, if the temperature is toolow, the meat would be difficult to bone.This is strategic in the global operations becausedifficulties in the separation phase could slow theproduction process down, affecting the whole supplychain. Moreover, if conditions are not optimized, partof the meat could remain on the bones, causingconsiderable waste that affects the overall business.

Growing Together

Because of this, Amadori is especially focused ondeploying systems that are able to optimizetemperature management during the processing andstocking steps. “That is why – says Carlo Caramanico,software support, Cid Engineering – Amadori hasbeen investing in high performance control solutions, ableto support the company’s business and expansion. At endof the past decade, we got in touch with Amadori for theupgrade of existing Wonderware InTouch HMI.”This mutual collaboration consolidated during theyears, and Cid Engineering has been supporting allAmadori’s upgrades and deployment of newplatforms and functionalities. “In recent years, – saysCaramanico – Amadori has always been asking for themost innovative solutions, aware that technologicalinnovation allows us to remain competitive on themarket. And this goal has led us to the deployment ofWonderware solutions. This choice has been determinedby the fact that, as qualified partners, we are highly

48


Food & Beverage

Figure 1: Packaging Line.

experienced in these applications and that, during theyears, Wonderware has been introducing new innovativesolutions, able to meet the demands of the highlycomplex Amadori’s business.”

Quality and Savings

Temperature management has been accuratelystudied over the past years, specifically its effect onsavings and energy efficiency. The old system wasbased on simple thermostats, which is characterizedby excessively slow response. Wonderware InTouchHMI (Human Machine Interface), on the other hand,allows smart operation. The system is able tomanage the activation of the conditioning systemaccording to actual needs. It also establishes thepower needed to guarantee the ideal conditions.Aside from temperature values, air quality andhumidity must also be taken into account. Humidity,in particular, must be kept within pre-set values, inorder to preserve a healthy environment for theoperators in the processing plant. The WonderwareInTouch HMI nodes help analyze environmentalconditions, helping in the control of theairconditioning system.It is the ability to operate effectively that allows thesystem to turn on and off according to the differentworking cycles, in both the automatic calculations.By evaluating the external conditions, the systemdetermines the time necessary to reach the righttemperature according to actual needs. Thisprevents early cooling of certain environments andeliminates the postponement of processing becauseoptimal conditions are not met.

The History of Temperature

The optimization of environmental metrics has astrong impact on product quality and the workingconditions of operators. It also plays a decisive rolein precise food traceability. Industry regulationsrequire a trace back of all the operational conditionsfood has gone under, and the authorities usuallycheck this information. In many cases, big customerswant to verify the contractual compliance of theproduction processes.In the past, all these values were entered manuallyby the operators. But this way of working causedconsiderable problems, both for the need ofemploying extra operators who manually transcribeinformation, and for the high risk of humantranscription errors. The Wonderware Historiansoftware is specifically designed for thehistoricization and archiving of process data andhelps solve this problem. ActiveFactory softwareaccesses all this information and transforms it intographics and useful information that allow operatorsto visualize historical event-related temperaturetrends intuitively. This feature helps with traceabilityand it also allows the operators to be immediatelyinformed about abnormal situations. In this way, it ispossible to act timely in case of deviations from setvalues, often before problems occur.The high scalability of the solution, initially onlyimplemented in limited departments, has beensubsequently painlessly deployed in all the otherprocesses, thus ensuring the optimization of theproduction cycle and energy management in theTeramo plant.Recently Amadori chose to replace the old S5 PLCwith a the newer Siemens S7 PLC. This has beensuccessfully implemented without affecting theWonderware automation solution. Once the newhardware had been configured, it has beenimmediately deployed, with no implication on theproduction cycle. Thanks to the most innovative and advancedtechnologies, it is possible to ensure the highestefficiency levels that always ensure high qualityproducts.

This document was realized thanks to the support of:Gruppo Amadori and CID Engineering.

49


Food & Beverage

Figure 2: Aerial view of Cesena plant.

www.indeff.com

YOUR MES PARTNER FOR EMEA

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INDEFF implements and supports all Wonderware MES solutions:

> Performance Management> Operations Management> Flexible Batch Management> Quality Management

Our services include consultancy and expertise to support international and multi-site customers to achieve their operational objectives and to defi ne an optimal MES solution architecture with a roadmap to operational excellence.

Exclusive focus and expertise on Wonderware MES solutions to improve operational excellence


Coca-Cola Fortune (Pty) Ltd.www.cocacolafortune.co.za

“The plant now has real-time visibility acrossprocesses and equipment and a much higherlevel of operational data integrity, while beingnearly paperless.”

Danie Tredoux, Division Project Manager, Coca-Cola Fortune

A refreshing look at business for Coca-Cola Fortuneby Wonderware Southern Africa

Goals: • To achieve the lowest unit cost in Coca-Cola

Fortune and also to establish a number of new bestpractices for Coca-Cola Fortune and Coca-ColaSABCO;

• To achieve the highest labour productivity and plantefficiency (OEE) as well as lowest energy cost andwater usage.

Challenges: • Integration with non-OMAC compliant OEM

equipment;• Tight time constraints;• A tight budget;• Integration with Coca-Cola Fortune’s IT

infrastructure.

Wonderware Solution: • ActiveFactory software;• InTouch HMI;• Wonderware Operations software;• Wonderware Performance software;• Wonderware System Platform.

Results: • Coca-Cola Fortune’s Bloemfontein plant now has a

nearly paperless environment that will reduceadministrative load and that, together with bettermanagement information, will drive efficiency upand costs down;

• The plant now has great visibility into its equipmentand process performance as well as a high level ofprocess and information integrity.

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Port-Elizabeth, South Africa - Coca-ColaFortune is one of 4 Coca-Cola licensed bottlersoperating in South Africa. The plant is located inBloemfontein. Coca-Cola Fortune is responsible forapproximately 23% of the total SA Coke and relatedproduct sales. The business is expected to sell 7.5million hectoliters or 66 million cases of beverage in2009, utilizing 14 production lines.

Coca-Cola Fortune is part of the Coca-ColaSABCO business entity which is licensed by Coca-Cola to bottle in 12 different African and Asiancountries. Coca-Cola SABCO, with the GroupOffice in Port Elizabeth, has an excellent reputationfor product quality and bottling excellence.

Whatever its financial position, the world can stillenjoy a Coke and the company responsible for morethan 20% of South Africa’s enjoyment of Coca-Colaand hundreds of other refreshing products is Coca-Cola Fortune, part of the Coca-Cola SABCO group.

With an annual production of 7.5 million hectolitresacross 344 products and 14 production lines, Coca-Cola SABCO looked to a Manufacturing EnterpriseSolution (MES) system from Wonderware to managecomplexity, improve efficiency and reduce costs atits Bloemfontein facility.

Coca-Cola Fortune Cheetah plant in Bloemfonteinis the first plant in Coca-Cola Fortune to implementa MES system. Apart from the usual extensive MESfunctionality, the system was chiefly to focus on

batch tracking, line performance, operationsmanagement and Overall Equipment Effectiveness(OEE) functionality. This was a Greenfield plant thatcould capitalise on available technologies while therest of the group used mostly manual or semi-automatic systems.

Business Objective

“The objective with the Cheetah plant was to achievethe lowest unit cost in Coca-Cola Fortune and also toestablish a number of new best practices for Coca-ColaFortune and Coca-Cola SABCO,” says Ryan vanKerkhof, Manufacturing Unit Manager, Cheetah Plant.“Key goals included highest labour productivity and plantefficiency (OEE) as well as lowest energy cost and waterusage to name a few.”

In order to achieve these business objectives,Cheetah plant needed easy-to-use operatorinterfaces, data analysis facilities, a ready link to ERPsystems (specifically SAP), product traceability, plantvisibility, the automation of bottling processes,remote access for support and query and in-plantinformation display.

Two of the notable aspects of the project were thelevel of customer cooperation during its designphase and the enthusiasm of the operational staffwho showed huge interest in its implementation.

Solution Selection

EOH Mining and Manufacturing, aWonderware system integrator, wasselected because of the company’ssemi-independent nature and its trackrecord in the same industry andaccumulated industry knowledge.

The software included Wonderware’srange of industrial automation and MESsolutions. It was a perfect fit becausethe adjacent plant was already usingWonderware software solution fordowntime analysis and it was alsodecided that the Wonderware offeringsprovided the required functionality.

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ActiveFactory software, InTouch HMI, Wonderware Operations,and Performance software, Wonderware System Platform.

Food & Beverage

Figure 1: Multi-level hierarchy of activities in a manufacturing enterprise.

System Architecture

The system architecture consists of the fullWonderware suite of products. In level 0, SiemensPLCs control the plant. In levels 1 and 2, theWonderware System Platform provides theinfrastructure on which Wonderware InTouch HMI(Human Machine Interface), WonderwareOperations software and Wonderware Performancesoftware (level 3) are implemented while alsoproviding integration between levels 2 and 4(figure 1).

The Wonderware products in use are based onArchestrA technology which provided the coreinfrastructure for the rest of the WonderwareOperations software and Wonderware Performancesoftware. InTouch HMI is used as a universalworkstation which provides process plant controland visualisation into the MES operations and thepackaging line performance. The universalworkstation concept allows InTouch HMIapplications for three different vendors to beintegrated into a single environment in order toprovide a unified view into the entire plant.

In excess of 20,000 tags are processed. There aretwo universal workstations with large LCD screensused for displaying line performance KPIs. Theoperational staff can control the plant as well asview historical process information and plant

operational information such asproduct genealogy. Line performance(performance, availability and quality)is monitored with OEE on someequipment whereas only theavailability parameter is measured onthe rest.

ISA-88 and ISA-95 standards wereextensively used in the developmentof the process control and equipmentmodels. The information from theproduction line was converted forvisualisation using an OMAC / PackMLstandard.

Of the extensive MES functionalityavailable, production execution,inventory control, traceability,

genealogy, quality states and yield control wereimplemented. “The ISA-95 activity models were used todefine the production, inventory and qualityrequirements,” says Barnard. “The MES softwareprovided the basis for the business logic and reportingfunctionality while the Graphical User Interface (GUI)was implemented using InTouch HMI in its role as auniversal workstation. As the system requires minimalinput from the operational staff to initiate and controlproduction processes, some of the business logictransactions were implemented using custom ArchestrAobjects.” (ArchestrA is Wonderware technologybackbone for all industrial, MES and ERPconnectivity applications).

The system is integrated with the company intraneton the reporting level, allowing multiple users toaccess production and line performance informationusing out-of-the-box reporting tools. WonderwareActiveFactory software (trending, analysis andreporting software) and Wonderware InformationServer (aggregation and presentation of plantproduction and performance data over the web orcompany intranet) are used. The ActiveFactorysoftware provides access to production processcontrol information while Wonderware InformationServer provides access to plant operationinformation. “The result of all this is that operationalstaff has full access to-real time and historical plantinformation,” adds Barnard. “From a system integrator’spoint of view, perhaps the most outstanding feature of

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ActiveFactory software, InTouch HMI, Wonderware Operationsand Performance software, Wonderware System Platform.

Food & Beverage

Figure 2: MES system overview at Coca-Cola Fortune, Bloemfontein.

the system is the ease with which applications, suppliedby different vendors using the same standards andplatform, could be integrated.”

System Implementation

Implementation started in December 2008 with atargeted sign-off date of end March 2009. Theproject was preceded by a URS development phasewhere the customer’s project team was enlisted todevelop the URS by applying the full ISA-95 standardin mapping Coca-Cola Fortune’s MES requirements.

“Some of the challenges that were thrown our way werethe integration with non-OMAC compliant OEMequipment, time constraints, a tight budget andintegration with Coca-Cola Fortune’s IT infrastructure,”says Barnard. “The whole system had to be developed,tested and implemented live and offline developmentwas done using VMWare technology with a simulationengine to provide the relevant data.”

According to Barnard, use of the ISA-95 standard provided an excellentframework for defining the MESrequirements and working closelywith the customer’s outsourced ITdivision ensured that all internalpolicies were adhered to with respectto the installation of networkinfrastructure, switches and fire-walls.“Something else that helped was the useof a unified standard on the WonderwareSystem Platform and visualisation systemwhich ensured ease of integration and aunified HMI experience for theoperational personnel,” says Barnard.

Benefits

• Coca-Cola Fortune’s Bloemfonteinplant now has a nearly paperless

environment that will reduce administrative loadand that, together with better managementinformation, will drive efficiency up and costs down;• The plant now has great visibility into itsequipment and process performance as well as ahigh level of process and information integrity.

Conclusion

By reconciling business needs with productionrealities, MES is the ‘information switchboard’ for amanufacturing or mining company. Where businessprocesses are interested in financial and customerissues and the shop floor is interested in productionand technical issues, MES handles the information inwhich the entire company is interested. And, asshown at this plant, by dealing with facts in real-time,MES can’t ‘fudge the books’ and provides the rightkind of decision support information to the rightpeople at the right time.

This document was realised thanks to the support of:Deon Barnard, MES Business Development Manager, EOH Mining and Manufacturing.

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ActiveFactory software, InTouch HMI, Wonderware Operationsand Performance software, Wonderware System Platform.

Food & Beverage

Figure 3: OEE dashboard for a filler showing drill-down capability to pinpoint the reasonfor non-performance.


Elledi S.p.A.www.elledi.com

“The solution we chose delivered consistent value-added benefits, especially thanksto the ability to differentiate. It has enabled us to fully monitor the entiremanufacturing process, with data available at our enterprise system. As a result,despite our complex range of products, real operating data enabled us tomaintain our competitive advantage.”Marco Carlon, Systems Engineer, Elledi

Wonderware, a valuable choice in a Biscuit and Bread Plant’sTraceability System by Wonderware Italy

Goals:• Increase competitive advantage by improving

process quality and reliability.

Challenges:• Increased complexity of production lines;• Compliance with product traceability regulations;• Reduce operator interactions.

Wonderware Solution:• ActiveFactory software;• InTouch HMI; • Wonderware Equipment Operations Module;• Wonderware System Platform.

Results:• Competitive advantage thanks to the availability of

complete information supporting decision makingprocesses at all enterprise levels;

• Reduce production costs (reduce operatorsworking on production lines);

• Higher product quality (reduce operatorinteractions and improve process hygiene);

• Full product genealogy;• Data availability to optimize maintenance

scheduling.

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Galliera Veneta (PD), Italy – Elledi wasfounded in Galliera Veneta, a small municipality of6,800 people in the province of Padua in 1968. Itswafer biscuits immediately found success thanks tothe company’s high standards of manufacturing andingredient selection. New lines for the productionof lady finger biscuits and shortbreads were addedin 1988, supplementing the original plant. A newplant was opened in 1995, alongside the historicalheadquarters, to produce a whole new range ofpastry delicacies, that includes tarts, tartlets,doughnuts and soft cakes.

Elledi currently manufactures its products - ninewafer biscuits production lines - in 13 plants,covering an area of 25,000 m2. The companyemploys more than 130 people who produce anaverage daily output of around 800 tons of product. Elledi has remained competitive by keeping anassortment of products available in various sizes,placing special emphasis on packaging that ensureslonger product preservation. To keep pace with theincreasingly demanding market, Elledi focused onimproving the general automation of its productionproceses by carefully chosing solutions to adopt andworking with technological partners.

Automatize to Optimize

Elledi decided to build a new Wafer Cream plant,alongside an existing facility producing batter. Theincreased complexity of the production linesrequired the deployment of consistent andrepeatable processes that provide quick and easycontrol over the lines. Product traceability was alsoa very important requirement and Elledi required acomplete monitoring of the whole productionprocess, in order to track information about the

products, including its history and genealogy.To solve these requirements, Elledi chose aWonderware software solution. Wonderware Italysupported Autoware, the first WonderwareArchestrA-certified system integrator in Italy, tocreate the solution that would satisfy themonitoring and traceability requirements of the newplant.

The installed solution consists of the WonderwareSystem Platform, InTouch HMI (Human MachineInterface), Wonderware Historian, ActiveFactorysoftware and Wonderware Equipment OperationsModule. The Wonderware System Platform is theheart of the solution. Its easy-to-use object-basedfeatures have enabled Elledi to reduce developmenttime. Wonderware System Platform’s common-layerfoundation enables different components of themanufacturing system to communicate. This includesthe integration to Elledi’s business system and all thedevices in the plant floor.

“Using the Equipment Operations Module enabled us toreduce our engineering and development times and ithas given us excellent results. The object-orientedprogramming and the genealogy functions are incrediblyeffective!” said Eng. Federico Di Prima, Autoware. The ability to analyze field data, making themavailable to the highest enterprise levels, has beencrucial for the creation of a really smart decisionsupport system.

A Winning Approach

Wonderware InTouch HMI software providesmonitoring of all manufacturing information andcontrol of the plant floor. Everything is constantlymonitored by operators so that problems are easilydetected. ActiveFactory enables Elledi’s plantpersonnel to analyze and report on historicalinformation. At any moment it is possible to viewproduction trends and this enables operators toproactively intervene in case of alams. On the otherhand, ActiveFactory web portal software enablesvisualization of reports and inventory stocks.

Every person in the plant is provided with mostuseful and relevant information.The high level of

ActiveFactory software, InTouch HMI, Wonderware EquipmentOperations Module, Wonderware System Platform.

Food & Beverage

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control and access to information is a competitiveadvantage that enables faster decision making.

From the Ingredients to the Recipe

The production process involves different phasesthat includes ingredient storage, dosing, mixing andproduction.The production process starts when the ingredientsare received and stored. In order to maintain highproduct quality, the ingredients must be mixedaccording to precise doses. Every work order ismade of subrecipes - one for every machine or plantinvolved in the production process - contained inelectronic records. The Wonderware Historiansoftware records all variables involved in theprocess (weight, time and material selection) andcreates a centralized recipe database. This enables allproduction managers to set machine set-pointsaccording to consistent and standardized metrics. The Wonderware solution developed by Autowarecontrols the mixing, refining and cream production,tank storage and dispatching to the respective lines.Data on ingredients used in every batch necessaryfor traceability are automatically collected by oil andpowder dosing systems. The Wonderware sofware solutiuon supervises themanufacturing at the wafer batter plant. Recipestorage and recall for batch coordination is providedby the Wonderware Historian software. Thesupervision and control system of the manufacturing

facility directly communicates with theMES system, exchanging information onfood production lines at every givenmoment. This enables the MES system tomonitor the traceability of semifinishedproducts, up to the manufacturingprocesses.

Traceability Means Quality

The capability to control the wholeproduction process in real time offersmany advantages. Every deviation frompre-set values is immediately detected,enabling timely actions at the exact pointwhere the alarm occurred. Theproduction-line monitoring enables total

food traceability, helping to facilitate regulationcompliance. All production phases and metrics arestored, providing full product genealogy. Thisincludes the identification of single components,with the ability to trace back suppliers, batches andmanufacturing date.In today’s competitive and evolving market, evenmaintenance management has strategic relevance inthe success of every business. All shutdowns needsto be planned in advance in order to minimize theimpact on productivity. The Wonderware SystemPlatform enables constant reconciliation ofproduction values with stored and field data,preventing sudden interruptions in production andany situation that could negatively affect productquality.“The solution we chose delivered consistent value-addedbenefits, especially thanks to the ability to differentiate. Ithas enabled us to fully monitor the entire manufacturingprocess, with data available at our enterprise system. Asa result, despite our complex range of products, realoperating data enabled us to maintain our competitiveadvantage,” commented Marco Carlon, Elledi SystemEngineer. Today quality is not only measured onfinished products. It is measured on a company’sability to choose solutions and technology partnersable to create value.

This document was realized thanks to the support of: Elledi S.p.A. and Autoware S.r.l., ArchestrA-certified system integrator.

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ActiveFactory software, InTouch HMI, Wonderware EquipmentOperations Module, Wonderware System Platform.

Food & Beverage

Figure 1: Recipe list.


Frito-Laywww.fritolay.com

A Wonderware Solution Helps Frito-Lay Minimizing Cost onEnergy and Water by EST (Enerji Sistem Teknolojileri Sanayi)

Goals: • Monitor electrical energy, gas and water

consumption to minimize utilities cost;• Create consumption reports on all production

area and products.

Challenges: • It is difficult to collect information from

monitoring devices spread out in a large area toa central location;

• It is important to create a system that providesstandardized reports to different people comingfrom different parts of the factory;

• To save on energy costs, it is necessary to set thelimits of consumption for the coming months.


Results: • The Wonderware solution makes it possible to

monitor electricity, gas and water consumptionbased on the customer goals, actual spending andcost per product unit;

• The Wonderware solution enabled people to acteffectively thanks to web-based reports;

• The system enabled plant personnel to focus onoverspending problems that are easily corrected.

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“Now operators show pride because of thesavings they have reached”.

Abdullah Biçer,Maintenance Manager, Tarsus plant, Frito-Lay

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Tarsus and Suadiye, Turkey - Frito-Lay,established in 1932, is the world’s largest packagedfood producer. The company owns or leases over50 plants or production processing facilities all overthe world. Its parent company, PepsiCo currentlymanufactures and sells a powerful suite of brandsand distinct products that include Quaker Foods,Pepsi, Gatorade, Tropicana Juices, and of course,Frito-Lay chips.

In Turkey, Frito-Lay aims to produce the bestproducts on the market, reduce its enviromentalfootprint and create snack foods that appeal tocultural and local tastes. Factories in Turkey arelocated at Suadiye (Izmit) and Tarsus (Mersin). Both factories decided to monitor theirconsumption of gas, electricity, water and otherutilities in order to minimize their manufacturingcosts while being environmentally friendly.The project was in line with PepsiCo’s strongenvironmental awareness policy and both factoriesadopted to watch their consumption level veryclosely.

Plant Intelligence

Frito-Lay evaluated different HMI/SCADAmanufacturers and decided to use Wonderwaresoftware. Wonderware System Platform is now usedin the Tarsus plant and Wonderware Historian isused in the Suadiye factory.

The consumption data coming from energy meters,water gauges and gas meters are collected by theWonderware Historian. At the Tarsus factory, twolarge screens display both historical and real-timeconsumption of the production areas. Also witheffective utilization of the intranet, Frito-Laymanagers are able to monitor the system from theiroffices transparently. The operators at the plant canexamine their targets and observe if they are closeto the planned level of consumption. Maintenancepersonnel and managers are able to track overallsavings as well as over consumption.

The improvement on the operating procedure isnoticeable once the trends at the production area

are set. The Maintenance Manager Abdullah Biçerfrom Tarsus plant reports a marked increasedawareness about the utility consumption among theoperators. “Now they show pride because of thesavings they have reached,” comments Biçer. He alsoadds that the project had been realized with theclose cooperation of the project team as a livedemonstration of the famous PepsiCo motto ‘TakeOthers with You’.

Wonderware Information Server is likewiseextensively used to obtain real-time energyutilization reports for Suadiye plant.

Hakan Er, the Electrical Maintenance Supervisor ofthe Suadiye plant says “I can manage when I can

InTouch HMI, Wonderware System Platform.Food & Beverage

Figure 2: Reports (Tarsus plant).

Figure 1: Utilities’ consumption (Tarsus plant).

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measure”. He adds that in their plant they were ableto save 30% on water after they started to use theWonderware solution.

Observing Details

The Plant Intelligence system at the Tarsus plant isintegrated to the ERP (Enterprise ResourcePlanning). The production data from the ERP isconnected to consumption data coming fromWonderware System Platform. The Tarsus plant’sapplication monitors the Potato Line, Dorritos Line,Cheetos Line, Packaging Area, Cogeneration Plantand Waste Water Treatment Plant.

Real time online consumption, as well as target

consumption, are displayed in tables for each areawhere production, electric consumption, gasconsumption, and water consumption’s graphics aremonitored. Detailed alarms and reports providereal-time information to the people in charge,independently of their location in the plant, via webinterfaces provided by the Wonderware InformationServer.

In the near future, Tarsus plant will expand thesystem to include solar power, heat recovery,pressurized air and nitrogen.

Savings from consumption create a real value forFrito-Lay and they are very happy with theWonderware solution.

This document was realized thanks to the support of:Frito-Lay.


Figure 3: Biogas area (Tarsus plant). Figure 4: Factory general layout (Tarsus plant).


Huys Voeders N.V.www.voedershuys.be

“There are no compromises when it comes toproduct quality, food safety, safety on the shopfloor and environmental matters.”

Peter Bresseleers, CEO, INDEFF

Wonderware improves production versatilityby Wonderware Benelux

Goals: • To produce high-quality products offering food

safety guarantees; • Optimal control of the production process;• Greater efficiency;• Uniform user interfaces at every level and in every

production plant.

Challenges: • To upgrade the automation environment; • To retain and consolidate their position on the

market;• To streamline and automate the production process

in the three plants;• To record in full all produced and delivered

products.

Wonderware Solution: • InBatch software;• Wonderware System Platform.

Results: • A joint address and nomenclature list for all

systems;• Out-of-the-box integration with various

applications in production automation;• Easy configuration and maintenance of applications

by means of graphic tools;• Total traceability of all products delivered and

produced.

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Brugge, Belgium - Voeders Huys is a dynamicfamily business that has been active in the animalfeed sector for several generations. The company isspecialised in cattle, pig and poultry feed. The feed isproduced at two production sites, namely in Bruges(on the industrial estate at the port) and in France.

The production site in Bruges consists of twoproduction units: one plant produces pig and cattlefeed, and the other solely poultry feed, in order toavoid contamination. Cattle feeds are manufacturedat the site in France, together with various rawmaterials mixtures in accordance with thecustomer’s demands.

No Compromises

There are no compromises when it comes toproduct quality, food safety, safety on the shop floorand environmental matters. Goal-orientedautomation helps the Bruges-based animal feedproducer Voeders Huys (Huys Feeds) to producehigh-quality products offering food safety guarantees.The company recently decided to upgrade itsautomation environment, and opted for theWonderware automation architecture.

To meet the ever-changing demands of itscustomers, Voeders Huys has brought a wide rangeof animal feeds onto the market over the years. Toretain and consolidate its position on this market, itis constantly optimising the product range and theproduction methods – a process in which the choiceof a supplier able to provide a high-performance

automation system is an important decision. This iswhere Wonderware came into the picture.According to Voeders Huys, Wonderware waschosen because it offers a complete package, thusaffording the possibility of anticipating extensions inthe future.

The company chosen as system integrator wasINDEFF, a Wonderware Endorsed system integratorsince September 2008. For the Benelux thiscompany is the only ArchestrA-certified systemintegrator to have attained this level.

Competitive Advantage

To hold their own in the present-day productionenvironment, successful companies have realisedthat operational excellence results in a competitiveadvantage. One of the decisive factors in operationalexcellence is integration of the entire supply chain,with manufacturing systems being linked to businesssolutions. “Wonderware offers a complete softwarepackage enabling companies to chart the entireproduction process and performance in real time. Thismeans it is possible to step in where necessary andadjust the production process or production proceduresto market requirements. Installing a soundly integratedautomation system is a major step in building a reliableenvironment for attaining operational excellence. TheWonderware software makes it possible to give a real-time overview of both the production process andproduction data such as stock, goods movements, batchinformation, etc., in a very simple and transparentmanner”, says Peter Bresseleers, CEO of systemintegrator INDEFF.

Production Process According to theCompany’s Own HACCP Plan

Every feed-processing factory has to comply withcertain standards and the ever stricter requirementsin the field of food safety and health rules call foroptimal control of the production process. VoedersHuys is GMP+ certified for this. This means that theproducts and services meet the requirementsstipulated in the laws and rules and regulationsconcerning safety for persons, animals and theenvironment, and the specific requirements laid

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InBatch software, Wonderware System Platform.Food & Beverage

Figure 1: Setpoint.

down by the customers in the framework ofIntegrated Chain Management. The implementation and enforcement of these GMPmeasures are supplemented by the company’s ownHACCP plan.

Peter Bresseleers: “The production process hoversbetween the required feed values and the cost price, as aresult of which the various formulas have to be adaptedalmost every day. This means that efficient ‘formulamanagement’ with effective mixing is essential. Thecompany starts with the raw materials, which are storedin silos and are delivered for shipment in bulk or on palletsby ship or lorry. Then the various ingredients have to bedose-measured very accurately and (if necessary) groundaccording to parameters incorporated in the preparationmethod. Everything is therefore controlled on the basis ofthe formula. An interface applies the desired preparationmethod to the production process. After mixing (whichmust be optimal and in which the mixing time is vital)and if necessary the addition of liquids, fats, acids andother essential ingredients, the mixture is stored again ordelivered, or undergoes further treatment (e.g. processinginto granulate).” “The great advantage here is that work can be performedindependently of an operator, and this is to the benefit ofthe quality of the animal feeds. Owing to a limited storagecapacity and in order to be able to anticipate customerrequirements (Voeders Huys also meets specific feedproduction requests), a smooth through-flow isimportant and the company also works according to thejust-in-time principle. Loading and unloading, both in bulkand in bags, is also fully automated. This is done by meansof an interactive interface with the lorry driver who

automatically receives all necessary documents. Thistherefore rules out the need for an operator to bepresent” points out Bresseleers.

All Products are Now Completely Traceable

Peter Bresseleers: “The company used to work withseveral systems and needed greater efficiency and, inparticular, uniform user interfaces at every level and inevery production plant, for reporting, for the mixingprocess, for the preparation method, and so on. It wastherefore our job to streamline and automate theproduction process in the three plants. On the basis ofthe Wonderware System Platform, based on ArchestrAtechnology, we therefore developed an automationsystem for this customer, in which Wonderware IndustrialApplication Server constitutes the heart of theautomation platform. By means of programmablecontrols, coupled with the high-performance Wonderwaresoftware, the company now has technical ingenuity,flexibility and transparency to increase the productivity ofmachines, industrial processes and infrastructures.”

“Moreover, the system is conceived in such a away thatall produced and delivered products are recorded in fulland are thus always traceable. This traceability isparticularly important if and when problems arise.Thanks to the modular and flexible architecture,Wonderware meets the needs of even the most complexprojects within centralised and dispersed automationenvironments. Changes of applications on account ofprocess evolution pass off smoothly thanks to the flexibleinstallation and incorporation of hardware and software”continues Bresseleers.

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Figure 2: System overview. Figure 3: System overview.

Loss of Capacity is a Thorn in the Flesh ofEvery Production Company

When processes are developed, automationnaturally plays an important role. Wonderwareoffers software solutions ranging from very simpleHuman-Machine Interfaces to distributed SCADAsolutions and Manufacturing Execution Systems(MES). Peter Bresseleers: “Loss of capacity is a thorn inthe flesh of every production company. Tracing theselosses and making them visible calls for efficientrecording. One of the conditions for meeting theserequirements is therefore the continuous inspection ofreal-time data acquisition and the storage of data on allbatch procedures. In order to be able to guarantee thiscontinuity, Wonderware InBatch software was chosen.InBatch software automates product issue. A rapidswitchover from one product to another is possible.InBatch software implements the formula preparationprocedures and verifies the correct order of theoperators’ activities. This serves as a continuous

guarantee of product quality from one batch to another.The operator is also given a perfect overview of what ishappening and can follow every activity on one screen.By simply pressing on the screen, he/she can also consultand check more details per machine”.

Solutions Extremely Flexible and Very Easy toIntegrate

The combination of possibilities enables thecustomer/user to work out solutions that areextremely flexible and very easy to integrate. Design, building, development and protection of thestandardised applications for the integration ofoperational and enterprise applications, are easilydone by the customer. This comprehensive approachconsiders critical business-to-manufacturingrequirements such as, firstly, integration possibilitieswith various applications, ranging from small(er)sites to several sites, secondly, the necessarysecurity provisions for foreign IT environments, andthirdly, support of the most common standards. Andto give the customer even more support, a library oftemplates is provided for the integration ofproduction planning and performance measurementsystems with ERP, etc.

And our interlocutor concludes: “The strategy of bothWonderware and INDEFF is to offer added value in theautomation of our customers’ production process in theform of expertise and specialisation. The WonderwareSystem Platform manages all functional possibilitiesneeded for industrial software. This platform isspecifically designed for automation and informationtechnology staff operating in their demanding real-timeenvironments”.

This document was realized thanks to the support of:Huys Voeders N.V. and INDEFF S.A., Wonderware Endorsed systemintegrator.

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Figure 4: Scheme press.


Lotte SamKangwww.lotteSamKang.co.kr

“Wonderware InTouch HMI is much better thanI had imagined. We can make decisions twiceas fast.”

Shin U-Infra, Business Team Manager, Lotte SamKang

An Integrated Production Management System for the Food Industry by Maha Net Co. Ltd.

Goals: • To develop a new plant resource management

system capable of supporting decision-making withreal-time information and accurate reports of usageand operations.

Challenges: • The calculation of accurate manufacturing costs was

non-existent; • The old system wasn’t able to track claims;• Unable to collect operating and quality costs;• There are large losses from errors in manual

operation; • Lack of accurate operation analysis data;• Yield, operation rate, productivity, etc.

Wonderware Solution: • ActiveFactory software;• InBatch software;• InTouch HMI;• Wonderware Historian.

Results: • Information on resources are sent to the ERP

systems, with the additional ability of qualitymanagement tracking;

• Accurate calculation of unit product cost forcorporate strategic planning;

• The Wonderware solution has enabled the effectiveplanning of production activities.

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Seoul, Korea – Founded in 1958, Lotte SamKang isthe market leader in the Korean food market for thepast 40 years.

In 1960’s, Lotte SamKang established Korea’s firstsanitary facilities for the production of quality ice-cream with products such as the SamKang Ice Bar.

Since then they have produced many popular ice-creams such as JjuJju Bar, Amatna, Daeji Bar, Goo-Goo products, Hazelnut Café, Turtle Bar and manyothers.

Eventually, Lott SamKang ventured into themanufacture of other products like condiments tospecial restaurant sauces, instant meals, coffee, babyfood, bread and cookies.

Background and Objective

Lotte SamKang required a new plant resourcemanagement system capable of supporting decision-making by transparently reporting information onusage and operation of all on-site resources.

In addition to that, a real-time management systemwas required to strengthen the company’scompetency and develop new growth engines.

System Development Objective

Although the information system allowed theaccumulation of data and support for decision-making, there was a need for dynamic real-timeinformation management for field-oriented decisionsupport, tracking of various production resources,

and quality management.

Real-time Production Information Systemcapabilities

The capabilities of the integrated productioninformation system included a real-time interfacewith the existing ERP, a human machine interface(HMI) connection to the automated productionsystems, an automated warehouse managementsystem, and an enterprise asset management system.

Integration with Utility SCADA

All the PLCs at the Lotte SamKang plant areconnected to the HMI where each unit operationequipment can be individually managed.

A Wonderware Historian collects all real timeinformation.

The accumulated historian data is processed for useby the enterprise asset management system (EAM)or to the manufacturing execution system (MES).

The operating timedata automaticallyextracted from the fieldequipment istransferred to the EAMso that the workorders can beautomatically generatedin accordance with thepreventive maintenancestrategy.

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ActiveFactory software, InBatch software,InTouch HMI, Wonderware Historian.

Food & Beverage

Figure 2: Utility SCADA System Structure.

Figure 1: HAVC Utility Screen Example

Integration of all Production Data

The information on all raw and semi-raw materialinput are collected by the HMI/ SCADA system and

sent to the systems at the upper tier. They can betracked for quality management.

In addition, the utility usage information is recordedalong with the actual production, both by personneland by product, to get an accurate calculation of theunit product cost.

The collected information will also be used forcorporate strategic planning.

Production Progress MonitoringIn the past, an entire plant had to be patrolled inorder to determine the actual production status.With the new system, all the necessary informationis accurately displayed on the monitor in real-time.This makes production planning more effective andsaves on personnel and operation cost.

System Integration and Scalability

Lotte SamKang has considered the informationsystem right from the start of the constructionphase of the new plant and has invested heavily tointegrate all the components that make up thesolution.

The key feature of the solution is the dynamicconfiguration of the information system enabled byWonderware. Any changes resulting from equipmentor system addition can be easily adopted anddeployed.

This document was realized thanks to the support of: Lotte SamKang.

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ActiveFactory software, InBatch software,InTouch HMI, Wonderware Historian.

Food & Beverage

Figure 3: Use of System Operating Time by Enterprise AssetManagement.

Figure 4: Integration of all Production Data.

Figure 5: Utility Usage Status

Figure 6: Monitoring of Production Status in One View.


New Belgium Brewing Company www.newbelgium.com

Brewery with Progressive Reputation Makes the Most of Wonderware Softwareby Wonderware

Goals:• Install an Enterprise Manufacturing Intelligence and

Manufacturing Execution System that will improveinventory management, increase productionaccuracy and improve quality control.

Challenges:• Reduce time spent entering data and manually

checking the movement of materials; • The PLC-based batching system was not operating

at its full potential; • The clean-in-place (CIP) information was not

readily accessible;• Quality control procedures were performed by

hand.

Wonderware Solution:• ActiveFactory software;• InTouch HMI;• Wonderware Production Event Module (PEM);• Wonderware System Platform.

Results:• ‘Track and Trace’ capability enables tracking of any

product within 30 minutes;• Key Performance Indicator (KPI) scorecards

provide immediate information about performance; • Historical analysis enables optimization of energy

use;• Faster trouble shooting; improved response times

for corrections;• Early detection of product deviations;• Projected ROI for integration costs will be realized

within two years.

“From the administrativeperspective, we save a lot of time. And from a people’s perspective,we save a lot of frustrations. That’sthe number one benefit.”

Igor Valuyev, Chief Electrical and Automation Engineer, New Belgium Brewing Company

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Fort Collins, Colorado– While many

manufacturers todaywork to minimizetheir impact on theenvironmentand meet green goals,

few have been applyingthese practices for as

long as the New BelgiumBrewing Company. In addition

to long-standing programs to reduce, reuse andrecycle, in 1998 the company became the first windpowered brewery in the United States. Sustainabilityand utilizing innovative technologies are among thecompany’s core values.

This tradition of progressive thinking extends itselfinto New Belgium Brewing Company’smanufacturing processes, but it did not start thatway.

In the beginning, Jeff Lebesch, inspired by theBelgium beers he tasted on vacation, began brewingbeer in his basement. Soon after, friends andneighbors urged Jeff and his wife Kim to take theiroperation commercial. That was 1991, and the smallcompany tracked most of its information on paperand with internally-developed databases.

Early Success Brews Frustration

It wasn’t long before the popularity of beers like FatTire spurred New Belgium Brewing Company’sgrowth. With reporting and compliancerequirements increasing, the company found itdifficult, time-consuming and sometimes evenimpossible to gather all of the production-relateddata they needed to generate reports using theirearly systems.

Operators were frustrated by the large amount oftime spent entering data and manually checking itagain and again to track the movement of materialsthrough the manufacturing process. The PLC-basedbatching system was not operating at its full

potential and clean-in-place (CIP) information wasnot readily accessible. Quality control wasperformed by hand, slowing down an operationwhere the excellence of the product is the basis ofthe brand and can’t be compromised.

Igor Valuyev, Chief Electrical and AutomationEngineer, explains, “Operators used to do double entry,which is double work. I’d say a lot of operators spent30% of their time updating the paper.”

There was no doubt that New Belgium BrewingCompany needed better processes to trace eachbatch of beer through the manufacturing process.Management wanted to increase accuracy, decreasetime for data input and reliance on paperdocuments, and reduce the time required to accessand analyze information. The company was alsolooking for ways to improve inventory managementand training. And the new system would have to beeasier to use for both operators and management.

A Plan for Innovation and Improvement

The brewery contacted Orbis Information Systemsof Dublin, Ireland – a Wonderware systemintegrator with food and beverage industryexperience – and shared this lengthy list ofrequirements. New Belgium requested their help toconfigure a system that would enable smoother,automated collection of data as well as more in-depth analysis and understanding of it. Additionally,the brewer hoped to see improvements in energyefficiency, quality assurance and throughput.

Besides meeting these parameters, it was alsoimportant for the new Manufacturing ExecutionSystem (MES) to match New Belgium BrewingCompany’s culture.

The system’s scope is plant-wide – fulfilling NewBelgium Brewery’s ‘grain to bottle’ quality-controlrequirements and providing valuable decision-making data from the arrival of raw materialsthrough the bottling and shipping of the finishedproduct.

ActiveFactory software, InTouch HMI, Wonderware ProductionEvent Module (PEM), Wonderware System Platform.

Food & Beverage

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Better Visibility Brings IncreasedEfficiency and Quality

The new system using Wonderware softwareprovides extensive ‘track and trace’ capability and is anatural fit with New Belgium’s conservation andperformance goals. With the new solution, anybottle or tank of beer can be tracked back to all ofits inputs – finding 100% of them within 30 minutes.It uses Key Performance Indicator (KPI) scorecardsto provide immediate information about how eachshift is performing as well as how the plant is doingon a monthly or yearly basis. This real-time visibilityis critical because it enables operators to devotetheir resources to solving the right problems.

In addition to providing more reliable and timelydata, the system also aids in enhanced analysis, whichhas lead to increased quality control. Productdeviations are caught much earlier, trouble shootingis faster and response times for corrections haveimproved. Control charts are used topredict the longer-term outcome ofprocess changes. In a business where thereis no scrap – low-quality product literallygoes down the drain – Wonderwaresoftware is helping to make a significantdifference in product consistency.

Additional Operations Benefits

Once tracked 100% by hand, vital statssuch as temperature and pressuremeasurements were difficult to gather,hard to support and not easilyanalyzed. But not anymore. Today, NewBelgium Brewery’s system employsWonderware Historian software tocollect and store real-time andhistorical production data. PlusWonderware InTouch HMI (HumanMachine Interface) software with itsintuitive graphical interface makes

running the plant easier than ever before.Wonderware ActiveFactory software also plays akey role. Because of its versatility, it is foundthroughout New Belgium Brewery Company’soperation: production departments use it to analyzeand optimize energy use. Janitors use it todetermine temperatures in the rooms, facilitiesusage and cleaning requirements. Even theaccountants employ ActiveFactory software toextract batch data and alcohol content readings tomeet Alcohol, Tobacco and Firearms Departmentreporting and taxation requirements.

Beer brewing is an energy-intensive process, andwith the Wonderware system, energy conservationhas improved too. Steam, water and electricityconsumption is monitored continuously. The plant’slighting system is automated; when no one ispresent, light sensors automatically dim the lights orturn off unneeded banks of lights.

Bottom Line, It’s a GreatRelationship

With any new implementation, there arechallenges along the way. And Wonderwarehas supported New Belgium BrewingCompany throughout the entire project.Valuyev says, “I have used Wonderware formany years, and in my opinion they have thebest technical support system in the world.People are prompt and people get backto you.” Wonderware knows that thiskind of response builds strongrelationships.

As for return on investment, Valuyevspeculates that ROI will come withintwo years for the combined softwareand integration costs. Which workswell for a company that prides itself onenvironmental best practices andprogressive use of technology, all whiledelivering a high-quality product andoperating profitably.

This document was realized thanks to the support of: New Belgium Brewing Company.

ActiveFactory software, InTouch HMI, Wonderware ProductionEvent Module (PEM), Wonderware System Platform.

Food & Beverage


Orley Foods (Pty) Ltdwww.orley.co.za

“We found that the Wonderware solution was best suited as it had a proventrack record in food and beverage (we spoke to their customers) and was usedin many local and international plants involved with food production.”Henk de Villiers, Operations Manager, Orley Foods.

Orley Foods - world-class chocolate manufacturing with a little help from Wonderwareby Wonderware Southern Africa

Goals:• Full product traceability;• Seamless and transparent integration of

manufacturing and business systems throughout thecompany;

• Trend and trace process issues in order to speed uptrouble shooting while conforming to regulatoryrequirements.

Challenges: • Re-engineering of Orley Foods’ process control

and information delivery infrastructure;• The plant model would have to be designed to

handle the entire plant and not just certain aspectsof the chocolate production facility.


Results: • Consistent batch sizes; • Raw material allocations tracked; • Better process control tracking;• Significant savings in fat usage;• Standardisation of batch processing times;• Minimised batch/formulation corrections.

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Background

Orley Foods is fully HACCP (Hazard Analysis andCritical Control Point – an FDA programme)compliant and the company’s quality managementsystem conforms to ISO9001. Compliance is auditedregularly not only by Orley but also by the SouthAfrican Bureau of Standards (SABS) and it is withinthis context of mandatory regulatory compliancethat a material tracking solution was sought.

The Orley Foods plant is made up of four mainareas (Figure 1). From Raw Material Receiving toFinished Goods, tracking and traceability is key toregulatory compliance. This is especially true of thechocolate manufacturing facility which manufactureschocolate in bulk according to the specifications ofdownstream chocolate confectionery manufacturerswhose products are found on the retail market.

Project Objectives

“Before this project, we were working with a failingsystem while our multinational customers demandedmore traceability information,” says Henk de Villiers,Operations Manager, Orley Foods. “These largecompanies want certificates of analysis and conformityand can demand a full traceability report within twohours. They can also do flash audits on site withoutwarning and ask any questions they wish about anybatch. So we looked for a solution that would provideseamless and transparent integration of manufacturingand business systems throughout the company.”

The manufacturing system wouldhave to be capable of as yetundefined expandability, ease ofintegration and the ability toprovide data in context for thebenefit of more informeddecision-making. All theimportant, relevant andcontextual information was to bepublished to a portal for easyaccess by personnel who couldmake best use of it and it wasimperative that the system havethe ability to trend and trace

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Figure 1: Structure of Orley Foods, its chocolate manufacturing process, areas addressed by thisproject and Wonderware System Platform model classification of functional groups.

Cape Town, South Africa - Over the past 40years, this proudly family-owned, Cape-Town-basedbusiness has produced a comprehensive range ofquality ingredients for the South African foodindustry. The business has evolved into two distinctstreams, one involving the ongoing innovation,manufacture and distribution of Orley Products andthe other the highly collaborative, development-driven Orley Solutions service.

Orley Solutions is a dynamic and extremelyresponsive service through which the company’sNew Product Development division researches anddevelops food solutions for South Africa’s leadingbrand owners. Orley Products consist of a large range of successfulpackaged goods for wholesale distribution to thecatering, confectionery and baking trade, as well aslimited retail distribution to consumers.The company’s wide range of chocolate products(over 100 different formulations) include couverturechocolate made to international CODEX standards.

Needing to know the quantities of the costlymaterials that make up a batch of raw chocolate,Orley Foods selected Wonderware technology andthe capabilities it offers to allow for accurateconsumption and production monitoring per batchand to never again having to wonder about theconstituents of each batch. The merging of aneffective production solution with their newly-implemented ERP system gives Orley full visibility ondetailed manufacturing information per works orderand more effective decision support.

process issues in order to speed up troubleshooting while conforming to regulatoryrequirements.


In order to achieve its objectives, Orley Foodswould have to implement some far-reachinginitiatives that included the re-engineering of itsprocess control and information deliveryinfrastructure. Some of the considerations included:

• Traceability of fat usage and additionsagainst work orders - In the chocolatemanufacturing process, the different fats used areincompatible with one another so it is vital toensure traceability of the fat used at all times;• Monitoring / logging of process parameters -The chosen system would be used to monitor andtrack process parameters in the plant and for eachrecipe batch;• ERP integration with Syspro – Orley Foodsneeded one version of the truth for the Bill ofMaterials in order to minimise formulation failuresand so needed this information to be fed directlyfrom Syspro to the manufacturing system;• Overall system upgraded to latesttechnologies - As the company’s system could no

longer cope, it needed toupgrade to the latesttechnologies that would addressits Network and Windows / SQLServer environment as well as itsSCADA and PLC system needs;• Ingredient management ofrecipes - As Orley Foods hasover a hundred different recipesfor liquid chocolate includingdifferent colours and fatcombinations, the companyneeded a system that would beable to handle this variationseamlessly;• Introduction of expandablereporting infrastructure -With the new businessenvironment and the need forkey information, Orley Foods

developed KPIs to which the manufacturing systemhad to respond so as to deliver reports from acentral source.

Solution Selection

While realising that there were a number ofpotential technologies to address their needs, OrleyFoods decided to step things up a notch and lookfor prospective solution providers who could usethe technologies they though most appropriate tothe task at hand.

“We started the project by defining our needs and thendrew up a tender process allowing various vendors andsystems to be evaluated,” says de Villiers. “It was vitalthat we had a well-known system but it was equallyimportant that we had a Cape-Town-based systemintegrator who needed to have experience in thedevelopment of PLC, SCADA and databases, especiallySQL. It was also a prerequisite that the SI should haveprior experience in a food and beverage environmentand was well acquainted with the complexities ofworking in a HACCP environment. We chose AMRAutomations because they met all these criteria.”

Several prominent technology suppliers wereconsidered but eventually Orley Foods selected

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Figure 2: InTouch HMI screen showing the fat storage and transfer process.

Wonderware. “We found that the Wonderware solutionwas best suited as it had a proven track record in foodand beverage (we spoke to their customers) and wasused in many local and international plants involved withfood production,” says de Villiers. “We were alsodemonstrated examples of integration betweenWonderware production and control systems with ourchosen ERP system, Syspro. Lastly, there are numeroussystem integrators and solution providers with anextensive knowledge of the Wonderware suite ofsolutions which meant that we wouldn’t be stuck in thecase of an emergency.”

Solution Architecture

Wonderware System Platform, based on ArchestrAtechnology, was used to develop a model of theplant. “Although the project only addressed certainaspects of the chocolate production facility, we designedthe model to cater for the entire plant,” says Stefan laGrange of AMR Automations.

An important part of the project was the PLCupgrade where the previous PLC was replaced withan Allen-Bradley CompactLogix unit and BeckhoffEthernet TCP/ IP remote I/O units which AMRfound to be a good and rapid solution for upgrading

installations where PLCs couldbe kept out of harm’s way. “We design PLC programmes torun autonomously with nointerference from the SCADAsystem,” says la Grange. “In thiscase, the PLC runs the recipe andhandles the fat transfer routeallocation. Obviously, processes forwhich the necessary raw materials(e.g. fat) are not available are notstarted.”

Orley Food’s ERP system, Syspro,places the work orders into a‘holding’ or intermediaryWonderware Historianproduction database from wherethey are picked up by theSCADA system. The worksorders specify the raw materials

to be used as well as the tank and equipmentallocation / scheduling. Operators then use thedual-screen SCADA system (InTouch HMI - HumanMachine Interface) to view the state of all theconches in the system and the works orders theyare executing. “We use the SQL data grid fromWonderware to show the production plan which displayswhich work orders are queued or being processed and asimple click on the column headers will sort the displayaccording to the chosen criteria,” explains la Grange.“Operators can modify the execution time of workorders or switch machines for a specific work order ifauthorised by production supervisors. This is useful forbypassing breakdowns or maintenance problems.”

The Wonderware Information Server reportstabulate all aspects of work order status andproduction information such as temperature vs.pressure charts, process variations, timings andoperator interactions for traceability purposes.

Realised Benefits

• Consistent batch sizes – Previously, this couldbe a hit-and-miss- affair with corrections having tobe made for marginal or failed recipes. Today, that’sall in the past;• Raw material allocations tracked - What fat

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Figure 3: Orley Foods system topology for phases 1 and 2 of the project.

goes where? Previously this was done manually andprone to operator error;• Better process control tracking – Alarming(e.g. motor trips) are now available at the SCADAlevel as is trouble-shooting information(temperatures, pressures, grinding times, etc.) as wellas operator involvement;• Significant savings in fat usage - In thechocolate industry, Cocoa Butter is called LiquidGold because of its high cost;• Standardisation of batch processing times –Allows for critical evaluation of plant performancereduced consumption or resources, especiallyelectrical power;• Minimised batch/formulation corrections -Savings in having to add raw materials to batcheswhich could result in batches that were larger thanthe customer ordered and were therefore wasted.

Conclusion

Phase 2 of this project will capitalise on the gainsalready made and extend functionality across theentire plant while closing the loop with feedbackdirectly into the Syspro ERP system. Orley Foodshas shown itself to be a prime example of

adaptability in a more demanding world with aglobally-competitive marketplace. There’s no doubtthat the integration of information technology at thebusiness and production levels is helping thecompany deal with the mechanics of sustainedprofitability. But it’s doing much more than that. It’sallowing Orley Foods to focus on its original missionof delighting all of us.

This document was realised thanks to the support of: Henk de Villiers and Fiona Byrns, Orley Foods, and Stefan la Grange, AMR Automations.

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OSM Piatnica SMwww.piatnica.com.pl

Wonderware MES solution supports packaging process of cottage cheeseby Astor Sp.z o.o.

Goals:• To create a consistent reporting system for

production efficiency;• Real time monitoring of machine conditions;• To analyze productivity levels through OEE

monitoring;• To analyze production potentials and material

consumption.

Challenges:• To detect and eliminate the most frequent reasons

of packaging machines stoppage;• To improve the production management;• To replace paper work with electronic records.

Wonderware Solution:• InTouch HMI;• Wonderware Performance software;• Wonderware System Platform.

Results:• 8% OEE increase thanks to the detection of

weaknesses in the packaging process and lateroptimization;

• Quality and throughput increased;• Production order tracking enabled the quantitative

and qualitative control of packaged products;• Available information for managers thanks to

detailed reports.

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“Thanks to the information about equipmentefficiency and utilization provided by thereporting system, we are able to understandhow to improve our packaging lineperformance and increase our productivity”.

Andrzej JacakAutomation Service Supervisor, OSM Piatnica

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Piatnica, Poland - Timely reporting andproduction efficiency analysis, based on WonderwarePerformance software, has showed the weakestpoints of the packaging machine and enabled themanagement to take the right decisions to optimizeits work. Wonderware Performance software allowsto control all machine components and monitor theoperators’ work on every shift.

OSM Piatnica offers a wide stock of dairy productsand with 50% market share represents one of themarket leaders in the food industry. They producecottage cheese and other milk products which aredistributed into different regions of Poland. A business operation under a strict technologicaland sanitary supervision is one of the key to explainan undisputed success.

The company also adopted the most modernsolutions to effectively manage and control the plantfloor and production. Last section of cheeseproduction line is equipped with one of the mostefficient packaging machine in Eastern Europe. Inorder to optimize production management,supervision maintenance and the performance oftheir cottage cheese packaging machine, OSMPiatnica’s management team decided to implement aMES solution. They chose Wonderware Performancesoftware to address their production efficiency andstoppage analysis’ needs.

Thanks to the open and scalable ArchestrAarchitecture, OSM Piatnica was able to integrate the

new solution with the existing system. Moreover, thenew system automatically tracks machine status andcalculates its OEE (Overall Equipment Effectiveness).

Thanks to the Wonderware solution, it is possible toknow the most frequent downtime reasons andtherefore packaging operators, team leaders andmaintenance specialists can react immediately andprevent future production losses. With WonderwarePerformance software, it is possible to analyze themachine utilization and work cycles to implementpredictive maintenance. Selected packaging machineparameters are recorded in Wonderware Historiandatabase.

Existing visualization based on Wonderware InTouchHMI (Human Machine Interface) was extended toenable order execution and production balancing.

Thanks to Wonderware Performance software, thecustomer have access to comprehensive productinformation, from recipes and raw materials to thepackaging and ‘best before’ date printing.

Key Effects of Implementation

Unquestionably, the most reliable benefit fromWonderware software implementation is thecommon reporting system enabling maintenancestaff and the top management to have access to realtime and updated information from the shop floor.


Food & Beverage

Figure 2: Downtimes & Failures Analysis’ Report.

Figure 1: Top 10 Downtimes’ Report in Wonderware InformationServer.

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The new solution is a user-friendly tool: reports canbe created quickly and contains useful data on themost frequent downtimes, work status, maintenanceand balancing of the resources. “Thanks to the information about equipment efficiencyand utilization provided by the reporting system, we areable to understand how to improve our packaging lineperformance and increase our productivity. We knew itwas possible, but we didn’t imagine that improvementswould have been so easy to reach. Now we know that aproduction increase will not create bottlenecks,” said

Andrzej Jacak, the Automation Service Supervisor inOSM Piatnica.

Wonderware Information Server’s reporting systemensures the web-based access to the reports, as wellas to basic and current parameters connected withpackaged products. It is also possible to conductdifferent analysis, based on the real data fromanywhere, not only from the production plant.

It is worth to notice the easiness of applicationdesign and development thanks to the ArchestrAarchitecture and the simple management ofproduction orders. Thanks to the Wonderwaresolution, OSM Piatnica was able to minimize thetime needed to add new orders into the system.

By considering the results of the Wonderwaresolution implementation, OSM Piatnica managementteam is taking into consideration the possibility touse the same equipment and software automationfor packaging lines which will be installed in thefuture. “In the future we would like to add the reportingsystem to other machines and production lines, in orderto analyze manufacturing process completely,”summarizes Jacak.

This document was realized thanks to the support of:OSM Piatnica.


Food & Beverage

Figure 3: Work Order Summary at Operator Station.


The South African Breweries Limitedwww.sablimited.co.za

SAB Maltings adopts latest Wonderware technology for batchtracking and reportingby Wonderware Southern Africa

Goals: • Track products through the production process in

order to get a complete view with respect toproduction variables applicable to each batch;

• Reports detailing product transfer times and vesseloccupancy times.

Challenges: • The merging of production and process timelines

into a single source of information with all the datain context for meaningful numerical and graphicalreports regarding production KPIs;

• The safeguarding of existing system investments.

Wonderware Solution: • InTouch HMI;• Wonderware Equipment Operations Module;• Wonderware System Platform.

Results: • The new system has highlighted operational and

plant issues, which had previously been ‘hidden’from view;

• True vessel occupancies and transfer times can bedetermined;

• Providing real-time data in the correct format nowhas made users more aware of true realities andthey want more;

• Meaningful information is helping SAB Maltingsachieve its overall objective of continuous processimprovement.

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“All in all, for the first time, we now have anautomated system giving us the informationto achieve what everybody is striving for –continuous improvement.”

Eddie Jordaan, IS manager, SAB Maltings

Caledon, South Africa - SAB’s involvement in thebarley and malting industries in South Africastretches back more than a century but moving tomore modern times, barley growing started in theCaledon, Swellendam and Bredasdorp areas in theWestern Cape in the early 1970s.

Southern Associated Maltsters (SAM) wasestablished in April 1978 as a joint venture betweenSAB and two cooperatives. During the mid 1990s, asecond barley growing area was established underirrigation in the Vaalharts and Taung areas.In 2006, more than 800 farmers were planting barleyfor the malting industry. Caledon Maltings is nowone of the biggest in the Southern Hemisphere withan annual capacity of 180,000 tons. Caledon Maltingsruns a 24/7/365 operation. Every 14 to 16 hours, a306-ton batch of malt is produced. Each batch isequivalent to nine rail wagons and will produce 7.8million cans of beer. SAM is now called SAB Maltings.

SAB Maltings at Caledon (Western Cape Province)is a wholly owned subsidiary of the South AfricanBreweries Limited and has been operating since1981. The company’s business is to turn barley into180 000 tons of malt every year for the brewingindustry and that’s why it’s the biggest producer ofmalt in the southern hemisphere. With malt batches

exceeding 300 tons and taking nine days tocomplete, SAB Maltings decided to improve insightsinto its production with a batch tracking andreporting system from Wonderware.

Project Goals

“We needed a system that could track our productthrough the production process in order to get acomplete view with respect to production variablesapplicable to each batch,” says Eddie Jordaan, ISmanager, SAB Maltings. “From a user perspective, wewanted to supply a system that could generate a reportper batch detailing the production KPIs numerically andgraphically. In addition, we needed reports detailingproduct transfer times and vessel occupancy times. Thisinformation would assist us in optimising processes.”

From this requirement arose the need for a batchtracking system for production and process data.Previously, the system consisted of an InTouch HMI(Human Machine Interface) and WonderwareHistorian providing process data and some trendingbut there was a lack of production information andno automated reports.

So, the project objective became the merging ofproduction and process timelines into asingle source of information with all thedata in context for meaningful numericaland graphical reports regardingproduction KPIs (Key PerformanceIndicators). Another project requirement was thesafeguarding of existing systeminvestments.

Solution Selection

This last project requirement mandatedthe use of the latest offerings fromWonderware and this meant growing thesystem by adopting the WonderwareSystem Platform based on ArchestrAtechnology.

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InTouch HMI, Wonderware Equipment Operations Module,Wonderware System Platform.

Food & Beverage

Figure 1: Batch tracking and reporting system topology at SAB Maltings.

In addition, Wonderware Equipment OperationsModule would be responsible for capturing theproduction data that would then be stored in theWonderware Information Server while MicrosoftReporting Services would be used for thegeneration of the necessary reports.

This choice of solutions would provide seamlessintegration with the existing Wonderwareinvestment.

Wonderware Equipment Operations Module isdesigned to help improve the consistency andeffectiveness of plant operations by helping toexecute production activities consistently, as well asproviding accurate visibility into the status ofoperations.

It’s also used where there are demands for end-to-end traceability of materials, equipment and otherresources across production processes. Compatiblewith the ISA-95 industry standard, WonderwareEquipment Operations Module includes genealogyfunctions for correlating events and informationcaptured across multiple areas and processsegments.

“In view of the solution choice, we needed a Cape-Town-based and ArchestrA-certified system integrator thatcould provide a turn-key solution and that also had alocal support infrastructure,” adds Jordaan. “AMR

Automations was eventually selected after following astandard tender process.”

Solution Implementation

AMR Automations made a point of understandingSAB Maltings’ business requirements before startingany engineering effort. “Once we understood what wasrequired, we drew up a functional specification whichwas agreed upon and signed off by everyone includingthe production personnel,” says Andrew Rennie,director, AMR Automations. “This also applied to thereport layouts and content.” AMR Automations even went further through aFactory Acceptance Test for a complete simulationof the solution before starting any implementationin order to make sure that the system compliedwith SAB Maltings’ requirements in every detail. It took approximately one month to establish thebase-infrastructure on site.

“Although this is a hybrid solution featuring a legacyInTouch HMI installation connecting to newer SystemPlatform software, the integration is so seamless that youwould never know it,” says Rennie. “WonderwareSystem Platform’s underlying ArchestrA technologyallowed us to define and apply standards that reduceengineering effort and provide for its reusability. Notably,this is the first installation of the Wonderware EquipmentOperations Module in SAB.”

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Food & Beverage

Figure 2: The display of KPIs in real-time areas together with alarm status, all within the Wonderware Information Server framework.

Delivering the Information

• Wonderware Information Server provides for web-based delivery of information with security. Alongwith Wonderware System Platform, AMRAutomations had the opportunity to use theMicrosoft SQL Server technology and thiscombination proved to be a really effective way ofdelivering the required information to those whoneed it while making use of the Microsoft securitylayers;

• Microsoft Reporting Services’reporting functionality wasdesigned using Microsoft ReportingServices that provided interactivereporting with drill-down capabilityto view production and processdata;• Dashboards and KPIs arevisualised using published InTouchHMI graphics.

Results

• The new system has highlightedoperational and plant issues, whichhad previously been ‘hidden’ fromview;• True vessel occupancies andtransfer times can be determined;• Providing real-time data in thecorrect format now has made users

more aware of true realities and they want more;• Meaningful information is helping SAB Maltingsachieve its overall objective of continuous processimprovement.“The eventual solution exceeded my expectations,” saysJordaan. “The first version produced the desired reportswith about 80% accuracy. The inaccuracies were tracedto mainly operational and plant issues which weresubsequently identified and which we are currentlyaddressing.”

This document was realised thanks to the support of:Eddie Jordaan, IS manager, SAB Maltings.

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Food & Beverage

Figure 3: System Platform in action – ‘The model says it all’.

Industry: Metal Products

Alcoa Inc.www.alcoa.com

“If I had to summarise all the benefits into oneit would be that of migrating from a paper-based manual system to amechanised, computer one.”

Róbert Németh,OTC & MES Application Manager, Alcoa

Alcoa automates plant process control using Wonderwaresolutions in the foundry section of Amorebieta facilitiesby Wonderware Spain

Goals: • To customize Comprehensive MES solution

included in Alcoa Global Order to Cash initiative;• Schedule and work order management,

Specifications and actual values management;• Downtime and OEE analysis, Traceability and

Genealogy, ERP integration and Customized userinterface, business rules, graphical analysis andcustomized reporting.

Challenges: • Need to improve the efficiency; • Complete tracking of shop-floor operations and

inventory;• Replace legacy shop-floor system;• Part of global Order-to-Cash initiative, involving the

implementation of new ERP and shop-flooroperation interface.

Wonderware Solution: • Wonderware Operations Software;• Wonderware Performance Software.

Results: • Complete tracking of the work orders on the

shop-floor and inventory;• Ease of use regarding scheduling and work order

management on the shop-floor;• Efficiency visibility, showing opportunities for

process improvement;• Seamless integration with current systems (ERP,

Control systems, Chemical Analysis systems);• Improvement of Quality management operations.

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“If I had to summarise all the benefits into one,it would be that of migrating from a paper-based manual system to amechanised, computer one.”

Róbert Németh,OTC & MES Application Manager, Alcoa

Amorebieta (Vizcaya), Spain - Thanks toWonderware technology, Alcoa has managed toalign the commercial objectives of its Order-To-Cash platform with its manufacturing operations bydeploying a Manufacturing Execution System (MES)in one key part of its production line.

World Leader in the Aluminium Sector

Alcoa is one of the world leaders in aluminiumproduction and technology, with a presence in 35countries and over 200 offices. It currently has eightproduction centres located in various Spanishregions from where it serves innovative solutionsfor its clients in major international markets.

In particular, its plant in Amorebieta (Vizcaya) isAlcoa’s largest rolling plant in Europe and one ofAlcoa’s largest in the world. It supplies both finishedproducts to third party customers as well as semi-finished products to other Alcoa rolling plants inEurope.

It manufactures sheets, levelled coils and trimmedcoils for building & construction and industryapplications and a great variety of other products tothe European market.

It also produces high-quality aluminium coils for thehigh value-added products manufactured by otherAlcoa plants in Europe. i.e. foil, litho, closures andbright products.

With the aim of optimizing all its aforementionedactivities and facilities, Alcoa decided to implementa system to control in real time all factoryprocesses.

Although the aim at the beginning was to implementa MES throughout the plant, it has only beenimplemented in one of the factory’s two mainsections: the foundry, where the blocks or ingots areproduced as raw material for sheet operations,which is the second basic division of the plant.

The company chose Wonderware software toautomate and monitor all plant processes, therebyobtaining absolute control of all operations beingcarried out.

Integrated Solution into the Owned GlobalPlatform

As Alcoa OTC & MES Application Manager RóbertNémeth explains: “We were looking for a solution thatcould be integrated into our global platform to manageOrder-To-Cash (OTC) processes based on Oracleapplications.”

Given that the OTC platform encompasses allproduction activities, the company decided todeploy a Manufacturing Execution System (MES)solution that was able to respond to allmanufacturing and plant quality requirements andcould be integrated in a transparent manner withthe Oracle system that will be implemented in thenear future.

Alcoa already had a MES system deployed asstandard in some of its facilities in the USA. “This washow we chose the Wonderware software as a globalMES solution and began to work immediately on firstcovering the needs of the Amorebieta production plantand then later implementing the more global OTCproject, a stage that has not yet been completed.”In order to carry out deployment in the Amorebietaplant, the aluminium manufacturer required theexperience of Wonderware for the functioning anddevelopment of the application to manage theproject, as well as dedicating its own resources atthe development stage and relying on Sysmaker asWonderware ArchestrA-certified system integrator.

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Wonderware Operations Software;Wonderware Performance Software.

Metal Products

Figure 1: Production tab where the operator can see the work order’sproduction planning and respective attributes.

Global Project Challenges

Sysmaker is a Wonderware ArchestrA-certifiedsystem integrator and has wide-ranging experiencein the implementation of Wonderware’sHMI/SCADA, MES, EMI and SPC solutions.

“We have been working with Wonderware MES softwaresince 2004 and this was one of our main reasons forparticipating in this project to help the end- clientachieving operational excellence,” says Carla Costafrom Sysmaker’s Technical Department.

As part of the Oracle-based OTC global strategy,the project required the design of a new interface tointegrate ERP processes and manufacturingoperations, with the final aim of optimizing efficiency,completing the monitoring of operations andinventory and replacing the management system ofthe inherited plant.

After defining these parameters, the entire team,comprising Wonderware professionals, Alcoadevelopers and Sysmaker specialists, foundthemselves faced with certain challenges.

The project included optimizing the MES solution,which was already operational in other Alcoa plants,and implementing it in the other facilities destinedto have the same activity.

“But there were differences between the factories in termsof work methods,” continues Costa. “And so one of themain challenges involved reconciling criteria to obtain asatisfactory solution for local managers at Amorebieta.”

This difference in terms of process operations andmethodologies triggered the need to resolve certainsystem control interface parameters “specificallyrelating to communication with the machines via OPCand obtaining information relating to inactivity times, theOverall Equipment Effectiveness (OEE) system and thecarrying out of work,” points out Costa.

Stages and Personalization

Nonetheless, thanks to the great flexibility andpersonalization capabilities of Wonderwaresoftware, the challenges could be overcome as thedifferent stages of the project progressed.

Implementation was divided into various stages. Thefirst comprised defining the specific requirementsrelating to plant operations, then the softwarespecifications were established and nextdevelopment and the different test processes began. After obtaining final approval from the plantmanager and providing some training for the systemusers, the process moved on to the production andexecution phase, encompassing a brief adaptationstage.

The implemented MES solution includes theWonderware Operations software andWonderware Performance software, both based onArchestrA technology.

While the former provides consistent execution ofoperations by unit and line, WonderwarePerformance software is a component ofWonderware MES and includes functions that makepossible OEE (Overall Equipment Effectiveness)control via plant monitoring, encompassing anunlimited number of causes for equipmentdowntimes and calculations of their globaleffectiveness.

As already mentioned, Wonderware’s MES platformwas personalized to respond to the specificdemands of the Amorebieta factory: “Covering agendamanagement and job orders, control of already existingspecifications and values, OEE and inactivity timesanalysis, as well as process traceability and genealogyand future integration with the Oracle system,” stressesNémeth, OTC & MES Application Manager at Alcoa.

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Metal Products

Figure 2: Downtime tab showing the list of latest working status of themachine and its duration, depending on the filter chosen.

Therefore, the possibility of personalizingWonderware Operations software andWonderware Performance software not only affectsuser interface, but has also been extended toobtaining graphic analyses and reports on the basisof business guidelines.

Main Benefits

As Németh points out: “If I had to summarize all thebenefits into one, it would be that of migrating from apaper-based manual system to an automated one.” This automation of MES processes affects differentareas, encompassing major efficiency and easiness ofuse when it comes to schedule production tasks andcalculating production needs, greater visibility andtraceability and outstanding precision in inventorymanagement and integration with control processes.Consequently, the Alcoa factory in Amorebieta hasmanaged to achieve:• Full monitoring of job orders and inventory in theplant;

• Greater ease in terms of task distribution andorganization;• Visibility relating to efficiency, displaying theopportunities for process optimization; • Transparent integration with already existingsystems (ERP, control systems, chemical analysissystems);• Improvement in the quality of managementoperations.

Wonderware provided functional consulting atanytime and contributed to application developmentand integration with the remaining process controlsystems, working hand in hand with Alcoaprofessionals and Sysmaker experts.

Speaking on behalf of Sysmaker’s TechnicalDepartment, Costa concludes by adding: “Globalperformance has been very good, especially because wehave been able to deploy a highly personalized solutionto respond to the specific demands of the Alcoa factory,with smooth integration and without any majorincidents.”

This document was realised thanks to the support of:Róbert Németh,OTC & MES Application Manager, Alcoa, andCarla Costa, Departamento Técnico, Sysmaker, Wonderware ArchestrA-certified system integrator.

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Metal Products

Figure 3: Screen to schedule the slabs that are ordered by the clients. Figure 4: Screen showing how the operator can check whichcomponents are going to be used and the material’s availability for thespecific alloy’s work order production.


Hoco Chrome V.O.F.www.corusgroup.com

Wonderware System Platform gives clarity to Hoco Chromeproduction processby Wonderware Benelux

Goals: • To Simplify operation in the plant floor;• Enable the record of production history;• Make production data accessible to all plant

personnel.

Challenges: • The existing system uses traditional switchboards.

This prevents plant personnel to get a clear view ofwhat is happening in the plant.


Results: • Production information is easily retrieved in

Microsoft Office tools;• The Wonderware solution is so easy to use that it

is possible to be implemented by in-housetechnical service personnel;

• With the object-oriented system it is easy tomaintain and expand in terms of hardware andsoftware;

• The SCADA system can be remotely accessed.This provides transparency to the work floor atbusiness level and allows maintenance to besupervised from different locations.

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“Wonderware was selected due to our positive experience withWonderware Historian. The system is both user-friendly and flexible.Furthermore, a solid foundationhas been laid for our MES layerusing ArchestrA technology.This open and object-orientedsolution offers so much more!”

René van Rij, General Manager, Hoco Chrome

Velsen-Noord, The Netherlands – HocoChrome is a 50/50 joint-venture between Corus andthe Canadian Court Holdings Ltd. Hoco Chromerepairs the surface of rollers used by Corus toproduce pressed steel sheets.

‘We maintain rollers that are used to process steel intothin sheets,” explains René van Rij, Hoco, Chrome’sgeneral manager. “These rollers need to be quicklyreturned to customers such as the Corus plants,otherwise the production process halts.” The stressplaced on the rollers is great and Corus’ qualityrequirements are high. Rollers are often sent backagain to Hoco Chrome after only a few hours ofservice, where an electrical spark process restoresthe correct texture to the roller surface. “A rollerdoes not need to be smooth, instead it is slightly rough,”explains van Rij. “This ensures that the roller produces asort of dotted pattern on the steel sheets. This makesthem easier to process.”

The original production process was controlled byoutdated operating panels which did not allow therecording of process history. It was also not possibleto remotely see what was happening on the workfloor. This had all been solved with theimplementation of the Wonderware SystemPlatform with InTouch HMI (Human MachineInterface) clients. This open and object-orientedsolution also offers a connection to the ERP systemand detection of Overall EquipmentEffectiveness (OEE).

The manufacturing process at HocoChrome is controlled by PLCs. A couple of small changes wererecently made to plant operations. “The existing system still usedtraditional switchboards. This led to alack of ability to have a completeoverview of the plant. For example, wewere not able to find out the processsettings when investigating a customercomplaint,” continues van Rij.

This is similar to flying an airplanewithout a cockpit and black box. Inorder to give clarity to Hoco

Chrome’s work floor processes, a new solution wasrequired for operation, visualisation, and archivingprocess data.

Data Historian Bases on a Highly-AccessibleSQL Database

This problem was solved by installing WonderwareSystem Platform solution that incorporates theWonderware Historian.

“We are going to use the historical data to create qualityreports for our customers,” explains Van Rij. “They willthen be able to check whether a roller has received thetreatment that they requested. Furthermore, we can usethe Historian to trace causes of malfunctions. This willnot only benefit our delivery reliability, but it will also helpus to free-up hidden production capacity. Expanding themachine park will only be required in two years time.”

The activities on the plant floor can also be followedremotely by logging on to the SCADA system. “Thisis very convenient from my office, and it is useful duringmalfunctions. The maintenance of our installations isdone by HTD, which is Corus’ technical service. We usedto have to wait a long time if a technician had to comeall the way from Den Helder during the night. This is nolonger necessary, as I am now able to log on to theSCADA system from home using a secure connection,”

explains Ko Dirkson, HTD’ssenior technical assistant. “Thisproved to be particularly usefulwhen there were problems withstarting up the spark process. Iwas quickly able to see that thesolution rested in a cold start on aPLC.”Wonderware was selected tosupply the SCADA system dueto the positive experience withthe Wonderware Historian inCorus’ central waste processingplant. “We already had experienceof the Wonderware platform atHTD, but at Hoco Chrome weimplemented this package for thefirst time completely on our own.”

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InTouch HMI, Wonderware System Platform.Metal Products

Figure 1: Rollers to process steel into thinsheets.

User-Friendly and Flexible System

The system is user-friendly and flexible because thesoftware is set up to be completely object-oriented.“You can design separate operating components,including visualisation, at the level of the Object Server.Object orientation allows you to easily change similarcomponents in one go. You can also copy and reusecomponents which we used extensively when we put anadditional production line into commission,” points outDirkson. This flexibility is also important for futureexpansions. “You can easily add software and thismakes the automatic registration of the OverallEquipment Effectiveness possible.”

This is also echoed by Mark Satink, account managerat Wonderware Benelux. “It is possible to make a pop-up screen for each object that informs the operatorabout the source of a malfunction. These notificationscan then be used later for a Pareto analysis, in order to

determine which problems occur themost.”

Another future extension is linkingthe SCADA system to the HocoChrome and Corus’ ERP systems.“Each roller is treated separately for therequired roughness,” explains Dirkson.“At the moment, this information is stillentered by hand. It would be better ifthere was a MES layer that couldautomatically channel this informationto the recipe data. Thanks to the presentWonderware technology, we have laid asolid foundation for this futurecomponent. Other future possibilitiesinclude sending quality reports to ourcustomers electronically,” adds van Rij.“Handling questions and complaints can

also be done through the Wonderware MES layer.”

Main Benefits

1. The Wonderware Historian enables productioninformation to be easily retrieved in MicrosoftWord, Excel or Internet Explorer;2. The Wonderware solution is so easy to use that itis possible to be implemented by in-house technicalservice personnel;3. The system is completely object-oriented. Thismakes it easy to maintain and expand in terms ofhardware and software (e.g. for the latter, theaddition of an OEE cockpit and a connection withthe ERP system);4. The SCADA system can be remotely accessed.This provides transparency to the plant floor atbusiness level and allows maintenance to besupervised from different locations.

This document was realized thanks to the support of:Hoco Chrome v.o.f.

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Figure 2: InTouch HMI clients.


Otefal S.p.A.www.otefal.it

“Wonderware System Platform meetsall engineers’ requirements, andobject-based programming inparticular allows to developapplications in a fast and consistentway, with the possibility to reusecontent on new lines. And thanks tothe excellent results obtained by thesupervisory system of the liquidcoating line, the same applicationwill be reused in all production lines,taking advantage of its flessibilityand scalability.”

Luca Benedetti, Responsible for Automation Projects, Skyline

The New Color of Aluminumby Wonderware Italy

Goals:• Increase competitiveness on the international

market by improving efficiency and ensuring highquality standards.

Challenges:• Production lines are composed of equipment

provided by different vendors;• Heterogeneous supervisory hardware and

software.

Wonderware Solution:• InTouch HMI; • Wonderware System Platform.

Results:• Waste reduction thanks to the possibility to detect

nonconformity causes;• Increased competitiveness thanks to the reduction

in production costs;• Increased productivity thanks to timely detection of

causes and solutions to output failures;• On time deliveries thanks to detailed scheduling

and reorganization of production.

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“Wonderware System Platform meetsall engineers’ requirements, andobject-based programming inparticular allows to developapplications in a fast and consistentway, with the possibility to reusecontent on new lines. And thanks tothe excellent results obtained by thesupervisory system of the liquidcoating line, the same applicationwill be reused in all production lines,taking advantage of its flessibilityand scalability.”

Luca Benedetti, Responsible for Automation Projects, Skyline

Bazzano (AQ), Italy - Otefal is a companyoperating in the finishing sector that has achievedsuccess through continuous innovation intechnology, as well as in commercial and marketingprocedures. Otefal has specialised in aluminium coil-coating. The product is a perfectly flat, specialaluminium alloy sheet coated with an even layer oflong-lasting coating applied.

Innovative Supervisory System

Global aluminum demand constantly grew in the lastdecade. This material, in fact, ensures excellentmachinability and has a long lifecycle, as well asweighing 30% less than steel. All thesecharacteristics have been favoured by modernindustry, not least because they comply with greenregulations: aluminum is totally recyclable and this isone of the reasons why it has been so widely used.Thanks to these valuable properties, companies inthe field of aluminum production and processingchose to invest in expanding or stengthening theirproductions sites, driving the best from existingplants.

Otefal is a clear example of this trend: the companydeployed the most innnovative automation andcontrol technologies in the Bazzano plant, in theprovince of L’Aquila. This considerable investment

involved embossing, liquid and powder coating. Thecompany in fact used out-of-date automationsystems, which have been growing without specificplanning and often depended on vendors’ choices.

The innovative supervisory system allows touniform data collection and communications,monitoring coating processes in real time to preventany deviation from optimum quality.

Looking for Excellence

The existing lines, which the company decided tokeep, are composed by machines produced bydifferent vendors, each with different supervisoryand control systems. The existing automation systemwas based on different and often off-markethardware, without any documentation aboutcomponents.Such a situation involved high workloads sincecareful visual checks and continuous adjustmentswere necessary to ensure the high quality standardswhich characterize Otefal products. Furthermore,obsolete assets compromised the reliability of thewhole system, which risked sudden failures.In order to increase competitiveness on a globalscale, under the direction of Sabino Morra, ICTGeneral Manager, last year Otefal chose a partnerable to contrbute in increasing production efficiency

while ensuring quality standards.Otefal chose to work with Skyline,combining typically IT expertise withspecific industrial automationknowledge.

A Common Language

The wide range of hardware andsupervisory softwares “represented oneof the main challenges in thedevelopment phase,” explains MarcoAnzovino, Skyline owner. “Even thoughthis is a common situation in Italianmanufacturing companies, where rarelythere are unified automation solutionsand every single vendor offers its ownsupervisory systems.”In many cases, proprietary systems

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Figure 1: Shopfloor.

work perfectly on specific applications, but aredifficult to interface with plant HMI systems, sincethey are not based on international standardprotocols.

Furthermore, suppliers use different hardwareaccording to market opportunities.

This leads to overlaps increasing complexity andmaking the whole system unstable and unreliable.These limits are not compatible with modernoperational activities, where there is no room fordelays, mainly because they would affect the wholelogistic and production chain.

In this scenario, Wonderware System Platform hasproved winning, and has been used by Skylineengineers to develop the supervisory operatingstation with InTouch HMI (Human MachineInterface), allowing vector graphics visualization tocreate realistic plant representations.

Real Plant View

“In aluminum coating processes, which are characterizedby multiple variables,” explains Luca Benedetti, Skylineresponsible for the automation project “besides theautomation phase, supervisory operations has afundamental role. For this reason we chose WonderwareSystem Platform, enabling to create logicalrepresentations of the physical processes. Wonderware

solutions provide better performances thansystems by other vendors, and this is thereason why we’ve been working with them formore than twenty years. And we can confirmthis thanks to our experience in the IT field.Wonderware System Platform meets allengineers’ requirements, and object-basedprogramming in particular allows to quicklydevelop consistent applications, with thepossibility to reuse them for new productionlines. And thanks to the excellent resultsobtained by the supervisory system of theliquid coating line, the same application will bereused in all production lines, takingadvantage of its flessibility and scalability. Thisway was created a business system whichautomatically collects and analyzes field data,avoiding problems arising from manual datacollection, with the advantages of operating in

real-time and eliminating any manual error. Total plantmonitoring allows all authorized personnel to be alwaysinformed about any unusual situation. Line operatorsimmediately understood the potential of this solution,both enabling to prevent inefficiencies typical of a systemdeveloped without specific projects, and the risk forirreversible damage, very likely in heterogeneous and notbacked up systems.”

Smart Supervision

“Through the smart supervisory system developed bySkyline – explains Luca Centi, EDP Manager – all fielddata is collected in real-time and Wonderware InTouchHMI advanced graphic capabilities enable perfectmanagement of all activities. In this context, the intuitivegraphic interface allows operators to be timely informedin case of problems, with the possibility to analyze everysingle detail”.

“Data connection and real-time operator interactions –explanis Anzovino – are possible thanks to theinnovative Wonderware technology, enabling to integrate‘intelligence’ in the control systems, transforming rawdata into useful information. The system immediatelydetects downtimes and is able to notify output falls,indicating possible causes and solutions, in order toquicken maintenance interventions. All these capabilitiesallow to maximize efficiency, since they prevent any issuethat could affect production times. In a process where

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Figure 2: InTouch HMI screenshot.

any detail is planned, any delay negatively affects thewhole organization, with the risk to pay penalties to thecustomers. On the contrary, a smart system timelynotifies any disfunction, supporting managers in planningor reorganizing production, in order to keep to theschedule, without causing logistic problems. Datacommunication is quite useful also in maintenanceactivities. The system, in fact, is able to notify the need forinterventions scheduled by machine builders, uponreaching of a certain amount of working hours. But whatis especially crucial is the capability to detect production

falls or unusual trends, clear indicators ofproblems to be solved before they lead tourgent interventions which negatively affectproductivity.”

High Readiness

Wonderware System Platform satifies allOtefal quality requirements. Choosing toinvest on high quality production, secondquality is inacceptable, and everynonconforming piece is rejected. In orderto ensure high quality standards,operations must prevent waste. For this reason, Otefal needs a system ableto monitor every single workpiece in real-time and to timely intervene onnonconformity causes, thus allowing foreconomic advantages. Waste is drastically

reduced, mainly because this smart system allows todetect negative trends, notifying maintenancemanagers about the need for actions to preventnonconformities.

This operational approach also improves efficiencyand productivity, allowing to reduce costs linkedwith every single workpiece. This feature allows toincrease competitiveness thanks to lower productprices, all the while keeping satisfactory profitmargins.

This document was realized thanks to the support of: Otefal S.p.A. and Skyline s.r.l.

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Figure 3: InTouch HMI screenshot.

Industry: Mining

AngloGold Ashanti Limitedwww.anglogold.co.za

“The fuzzy logic rules can be and are implementedremotely from South Africa or anywhere else, savingtime as well as transportation and consultation costs.The benefit of fuzzy logic rules will increase in parallelwith the increase in unit run time, as well as compoundits improvement as variability is decreased.” Corné Lourens,Metallurgical Manager, Geita Gold Mine

Enabling intelligent operations at a gold mineby Wonderware Southern Africa

Goals: • Applying the corporate standard;• Standardising the control philosophy;• Improving the alarming and alarm logging for

analysis;• Maintaining a history of production data;• Providing for real time and scheduled reporting

and the production of those reports;• Implementing an Expert System based on fuzzy

rules to reduce process variation and improveproduction.

Challenges: • Remoteness of the site;• Extreme ease of operation;• Sophisticated expert control that also had to be

transparent and easy to understand.

Wonderware Solution: • ActiveFactory software;• InTouch HMI;• Wonderware System Platform.

Results: • The implementation of corporate standards; • A new roadmap for future projects;• A state-of-the-art control system with best support

and training infrastructure;• Greatly improved alarming – ensuring safety and

logging the triggers;• The right information allows the right people to

improve plant performance even when not on site;• Identification of bottlenecks (e.g. problems with the

discharge dilution density);• Full remote support and fuzzy logic rule changes

promote rapid improvements.

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Johannesburg, South Africa - In 2008, AngloGoldAshanti produced 4.98 million ounces of gold fromits operations – an estimated 7% of globalproduction – making it the third largest producer inthe world. The company has 21 operations and anumber of exploration programmes in both theestablished and new gold-producing regions of theworld. Geita Mine, based in Tanzania, is one ofAngloAshanti’s production site.

Geita first came into prominence as the site of aGerman colonial gold mine. A German goldprospector discovered the mineral in the early 1900sin the hills surrounding modern-day Geita town.

This and other discoveries triggered a gold rush inthe surrounding area, attracting German and nativeprospectors alike. The colonial governmentestablished a mine to exploit ‘Bismarck Reef ’. Mining activities significantly declined, however, whenGermany ceded control of its colonies to the Britishafter their defeat in World War I.

Geita regained its prominence in the mid to late1990s when the Tanzanian government opened themineral sector to foreign investment. A number ofmedium to large-scale mining houses, includingAshanti and Anglo American, conducted extensiveexploration activities in the surrounding areas.The most significant outcome of these

developments was the construction of the open-pitGeita Gold Mine, now owned by AngloGold Ashantiand the largest gold producer in Tanzania.The deployment of plant and technology at remotesites in Africa is prone to logistics complications,delivery delays and support problems yet;AngloGold Ashanti’s Geita Gold Mine in Tanzania isbecoming a model of productivity in spite of thesechallenges.

Background

In 2006, decreasing production at the mineprompted AngloGold Ashanti to investigate and tomake some hard business decisions. “The loss of skillsat all levels throughout the process plant necessitatedthe implementation of automated control as far aspossible to reduce variability and increase controlexpertise,” says Corné Lourens, MetallurgicalManager at Geita Mine.

AngloGold Ashanti decided to call in system integratorSystems Anywhere who had previously successfullyaddressed such problems for the company.“One of the first things we found was a control systeminstallation that required significant improvement inorder to handle the higher level of automation that theclient was looking for,” says Systems Anywhere MD,André Vuilleumier. “Some areas, like switch gear

configuration, did not conform withAngloGold’s normal practices; anexample in this plant was that arunning motor was shown in redbecause it indicated a hazard but astopped motor was green because itwas in a safe mode. This contradictedAnglo’s normal standard indicators.With the skills shortage and high staffturnover the mining industry isexperiencing, a standardised controlphilosophy would be key to consistentcontrol and smoother operations.” While upgrading the controlsystem and improving the SCADA,the project goals included:• Applying the corporate standard;• Standardising the controlphilosophy;

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Mining

Figure 1: Geita Gold Mine system topology.

• Improving the alarming and alarm logging foranalysis;• Maintaining a history of production data;Providing for real time and scheduled reporting andthe production of those reports;Implementing an Expert System based on fuzzy rulesto reduce process variation and improveproduction.

This was to be implemented using the latesttechnology while also providing for a maintenanceplan and 24/7 support of the control systemsoftware in spite of the remoteness of the site.

Solution Implementation

The software solutions chosen for the Geita Mineincluded an Expert System to be developed bySystems Anywhere which would run withWonderware Information Server, ActiveFactorysoftware as reporting tool, InTouch HMI (HumanMachine Interface) and Wonderware Historian, allhosted by Wonderware System Platform, based onArchestrA technology. Seventeen Allen BradleyPLCs would be upgraded to cope with the newenvironment.

“In order to make sure the customer got what wasneeded and to clarify the system design, we spent a lotof time on the User Requirement Specification,” saysVuilleumier. “We addressed everything from colourcoding to access levels and implementation deploymentschedules during planned maintenance stops to avoidunnecessary downtime. This was followed by a thin-slicesimulation which was approved by the client.”Part ofthe design was to keep all display screens as

uncluttered as possible whileproviding operators with thedrill-down facilities necessaryto view any level of detail. “Thisis especially true of the alarms,”says Vuilleumier. “With ArchestrAtechnology, alarm groupings andthe alarm tree are automatic andwe only show the alarms that arerelevant to the section beingmonitored, such as the ball mill.Then, using a Pareto chart, onlythe top ten alarms that must be

serviced are displayed and the system logs whoacknowledged each alarm. Previously, the unscreenedflood of alarms meant that they were largely ignored.”

According to Vuilleumier, a discipline whereby themaintenance team effectively and regularly attendsto the top three alarms in the Pareto chart canresult in significant improvements in plantproductivity.

Details on analogue alarms and values can beaccessed using the same drill-down facility andperformance trends can be examined throughhistorical analysis to help predict potential problemson various items of plant – a key feature whenspares availability is limited because of theremoteness of the site.

Expert System

An expert system can be defined as an operatorwho is always present, adheres to a controlphilosophy and maintains it at all times. In this case,such an expert operator needs to monitor the millload, mill feed, power consumption, trends, etc. andthen make a decision on whether to increase ordecrease the input feed rate. In other words, this is amulti-variable control system which is quite differentfrom the standard PID configuration. The Expert System takes over the responsibility ofchanging the set points from the operator andbrings the mill to peak performance by:• Filtering the process variables individually througha moving average and checking them against theirparameters;

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Mining

Figure 2: InTouch HMI screen showing a ball mill gearbox’s lubrication details (left) and the viewfrom inside the ball mill powered by the two 4MW motors shown in the graphic.

• Comparing the result of each variable against therules that are stored in the database and analysingthe result to determine whether the set point needsto be increased or decreased;• Applying a time interval that determines howquickly it needs to react to the rule to ensure thatproduction is kept consistent. It’s important to bearin mind that, in this environment, quick reactionstimes are essential but then processes need sometime (10 to 30 minutes) to settle before any furthercorrective action is taken.

“One of the benefits of this approach is its transparencyand simplicity,” says Vuilleumier. “Complicatedmathematics could be difficult to manage at site levelwhereas the fuzzy-based rules are more easily traced sothat operators can understand the control philosophy ofthe system.”

Information Delivery

The Wonderware Information Server facilitates theaggregation of large amount of plant data into highlyinformative production reports tailored toAngloGold Ashanti corporate requirements. Thisallows management to access the information fromsite and contribute towards improving theirperformance. The Wonderware Information Serveris integrated with the company’s existing IT

infrastructure and web portals andhas helped connect plant personnelso that they can access the entireplant record. Lab data can bemanually entered when results arereceived and it is synchronised inthe Wonderware Historian at thetime the sample was taken. “TheWonderware Information Server getsthe right people the right informationat the right time so that they canimprove plant performance even whennot on site,” says Vuilleumier.Individual users at Geita Mine havebeen assigned access to differentviews/areas beyond their normalscope to allow them to do their

jobs more effectively. Displays include KPIs,production reports, trends and published InTouchscreens and any information is available in one ortwo seconds. “Reporting options are unlimited,”continues Vuilleumier.

Benefits

The project spanned 12 months and the changeoveroccurred on a live plant during maintenanceshutdowns. Realised benefits include:• The implementation of corporate standards; • A new roadmap for future projects;• A state-of-the-art control system with bestsupport and training infrastructure;• Greatly improved alarming – ensuring safety andlogging the triggers;• The right information allows the right people toimprove plant performance even when not on site;Identification of bottlenecks (e.g. problems with thedischarge dilution density);• Full remote support and fuzzy logic rule changespromote rapid improvements.

“The production rate of the plant will benefit significantlyfrom the upgrade,” adds Vuilleumier. “Other AngloGoldAshanti sites have benefited similarly in the past and byidentifying the bottlenecks at Geita, we are aiming toimprove recovery time and throughput.”

This document was realised thanks to the support of:Andre Vuillemier, Systems Anywhere cc.

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Mining

Figure 3: Expert System in action. The set point to the feed belt (yellow) ensures optimal millperformance while the ability to predict overloads allows the system cut back on feed beforethey occur (light blue and green).

Industry: Mining

Assmang Limitedwww.assmang.co.za

“The standards enforced by Wonderware SystemPlatform are allowing us to describe plantobjects and their behaviour to reflect ourexperience and needs.”

Marius Malan, Control Systems Supervisor, Assmang

‘Proof of the pudding’ in action at South Africa’s newest ironore mineby Wonderware Southern Africa

Goals:• The monitoring of the new mine’s processes and

production infrastructure.

Challenges: • Fast track implementation in a massive greenfields

project that included nothing less than the creationof a mega iron ore mine from the ground up.

Wonderware Solution:• ActiveFactory software; • InTouch HMI;• Wonderware System Platform.

Results: • The definition and enforcing of standards means

that less engineering effort will be involved in themine’s planned extension phases;

• ArchestrA technology provided a multi-userdevelopment environment that allowed engineersto focus on complex applications rather than low-level operations.

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Johannesburg, South Africa - Assmang Limited isa South African company that supplies raw materialto the world’s steel mills and alloy plants. Most ofthe group’s production is exported to the Far East,Europe and the USA.Originally named The Associated Manganese Minesof South Africa Limited, the company changed itsname to Assmang Limited in 200. Assmang, which isowned equally by African Rainbow Minerals andAssore, currently has three operating divisionsstructured to handle its three commodities ofchrome, manganese and iron ore.The Khumani iron ore mine is situated in theNorthern Cape Province of South Africa and closeto Sishen.Assmang’s Khumani iron ore mine is anambitious undertaking by any definition. Completedin just two years from a foundation of Kalahari sand,Khumani is well on the way of becoming a principalplayer on the global and competitive world ofprimary metal production.

Background

Assmang’s new Khumani iron ore mine is situated inthe Northern Cape Province of South Africa andclose to Sishen. The Khumani deposits are amongthe best iron ore resources in the country in termsof quality and quantity. Based on current reserves, a

new mine producing 8,4 million tons annually wouldhave a life in excess of 40 years and at double thatcapacity, a life in excess of about 25 years.

By any standards, the Khumani mine is a giganticproject. Starting in June 2006 with a budget of R4billion, 60 000 cubic metres of structural concrete,10 000 tons of steel, 3250 tons of plate work and650 kms of instrumentation and electrical cablingwere forged together to form this mega iron oremine in just two years.

The Khumani mine project was to be implementedin two phases: • Phase 1 was to be completed in September 2008and would have a capacity of 8.4 million tons of ironore per year. Phase 1a, to be completed inDecember 2008, would have a capacity of 10 milliontons per year; • Phase 2 will have an annual production level of 16million tons and is scheduled for completion in late2010 / early 2011;• A possible further expansion to 22 million tons perannum is presently at the feasibility study stage.

The iron ore is mined from a series of open pits byconventional drilling and blasting before beingloaded onto trucks for hauling to the primary andsecondary crushers. From there, the ore is

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transferred by conveyor to stockpiles ahead of thebeneficiation plant. The run-of-mine ore is stockpiledon blending beds in two categories, ‘on-grade’ and‘off-grade’.

The on-grade ore is crushed, washed and gradedaccording to four size categories. The off-grade oregoes through an identical crushing, washing andscreening process, followed by a jig beneficiationplant to match its chemical composition with clientspecifications. There are 8 Geoscan on-line analysersinstalled at critical locations in the plant to monitorthe chemical composition of the ore in real-time, sothat immediate remedial action can be taken if theore deviates from the chemical grade requirements.Products are stockpiled ahead of a rapid load-outstation, which has the capability to load 342 x 100-ton wagons in 8 hours – that’s one 100-ton wagonevery 90 seconds. From there, the product is railed860 kms to the port of Saldanha Bay for export.

Solution Selection

DRA Mineral Projects were appointed as theManaging contractor for this project and EPCMcontractor for the plant and infrastructure. DRAMineral Projects is an engineering company thatspecialises in project management, engineeringdesign and implementation and has implementedsuccessful projects on five continents. DRAappointed system integrator Iritron for the

Wonderware SystemPlatform’s implementationportion of the project.Iritron was activelyinvolved in the systemsengineering,instrumentation designand PLC control systemsaspects of the scheme.

This was a natural choicesince African RainbowMinerals and Assmang havestandardised onWonderware industrialautomation solutions forall their SCADA, historianand plant web portalrequirements and Iritron is

a Wonderware ArchestrA-certified systemintegrator that has provided Wonderware solutionsand support to Assmang since 1999. “To effectivelymonitor this huge complex, we implementedWonderware System Platform which is based onArchestrA technology and includes Wonderware real-timeHistorian, the Wonderware Information Server webportal, ActiveFactory software, real-time productionperformance analysis and reporting software andInTouch HMI (Human Machine Interface) for theSCADA/HMI applications serving some 44 000 I/Otags,” says Iritron director Johann Pienaar. “Inaddition, we used the Topserver I/O Servers fromSoftware Toolbox to communicate between the PLCs andthe System Platform as well as MDT Software’sAutoSave for the change control management of all 63Allen-Bradley ControlLogix PLCs.”

“These solutions were chosen to give us comprehensivedata analysis facilities so that we could check productionstatus and identify potential problems at any time,” saysMarius Malan, control systems supervisor, Assmang.“We also need continuous operation without loss ofcontrol or data as well as web access facilities and linksto our planning and ERP systems. Most importantly, it allhas to work through a user-friendly and intuitiveoperator interface. But these are all things we need to donow. This is a brand-new mine with a long future and wewill need to adapt production to meet with marketdemands. That means we’ll have to expand the systemas and when required and we’ll also have to do it quicklyand at minimal cost.”

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Figure 1: Part of the system topology at the Khumani Mine.

System Implementation

Allowing for the expansion of systems at minimalcost is a cornerstone of ArchestrA technology andone of the ways this happens is through thedevelopment of standards.

Standards allow companies to define, apply andenforce their engineering criteria so that everyoneworks from the same page. Standards also mean thatplant objects are built from templates and thatchanges to a single master template can bepropagated to every instance of that objectthroughout the plant.

“The standards enforced by ArchestrA technology areallowing us to describe plant objects and their behaviourto reflect our experience and needs,” says Malan. “BeingAssmang standards, they reflect our best practices andcan be used by other companies in the group. Theenforcement of standards ensures that all futuredevelopment conforms to the norms already developedand this will save engineering time in the future,especially with the planned extensions to the plant.”

Standards do not only apply to plant objects but alsoto the whole plant and to integration with otherdisciplines in the company. One of the key standardsthat help businesses build a coherent organisation isISA-95. “Khumani’s plant model is based on the ISA-95standard which was facilitated by Wonderware SystemPlatform and its best practices guide supplied by

Wonderware Southern Africa,” adds Pienaar. “Thisstandard was implemented and adhered to throughoutthe project and will greatly facilitate integrating thesystem’s information with Assmang’s planning and ERPsystems.”

Another important Wonderware System Platformattribute that safeguards expansion at minimal cost isthat of scalability. At Khumani, they know they willhave to double their capacity in two years and, inordinary conditions, this could mean some expensivesystem rework. “When the time comes to expand thesystem, the initial work done on standards means thatdefining new capability will be a matter of hours ratherthan weeks or months,” says Pienaar. “In addition,Wonderware System Platform has been proved to handlemore than a million I/O tags and we’re currently lookingat (only) about 44 000. This, together with a self-configuring historian, makes system expansion painless.”

Assmang’s Khumani mine, a major contributor tothe company’s financial well-being, can’t affordunplanned production delays during its lengthy andproductive life. The mine has to produce qualityproducts that will be accepted worldwide in anextremely competitive market and to do that, itneeds industrial information and automationequipment equal to the task.“Wonderware System Platform’s management of dualredundancy procedures not only guarantees delivery ofdata to the Historian but has saved us a significantamount of complex software engineering to resolve this

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Figure 2: Load-out stacking and Load-out mimic (dual screen).

critical issue,” says Malan. “In fact, we no longer think‘redundancy’ but rather of decisions that have to bemade given the wealth of available information – inother words, forget the technology and focus on thebusiness.”

Apart from standards, scalability and systemavailability, Assmang needs a few more keyattributes from a system in charge of one of itsprimary wealth-creating facilities and these aresecurity and architectural freedom – which don’tmean much if said quickly but are key to versatilityand freedom of choice. “In a situation such as ours, it’s important that onlyauthorised personnel has access to various levels of thesystem to make changes to set points and otherparameters,” says Malan. “With Wonderware SystemPlatform, security and alarming are uniform across theentire system and we don’t have to make provision fordiscrete sub-systems. Of equal importance is our abilityto change our mind with respect to the structure of oursystem and its interaction with others. ArchestrAtechnology gives us that choice. For example, we had tointegrate with a number of third party stand-aloneInTouch HMI applications incorporated into the Metsocrushers, the Bateman load-out station, a QMastor

stockpile management system and a CCLAS LIMSsystem. Well, it all just ‘happened’”.

Conclusion

“For us, the most significant aspect of this project wasthat ArchestrA technology gave us a multi-userdevelopment environment that allowed us to design,develop, implement and maintain a large project in oneyear,” says Pienaar. “Wonderware System Platform’sintegrated development environment gave us the tools todevelop complex applications without botheringunnecessarily about the details of interfacing with PLCsat one end of the spectrum and ERP systems at theother while providing the functionality to do both.”

From the start, Assmang’s Khumani mine is a winner,not only in terms of its rich deposits but also interms of how it will process them. Today, noenterprise can survive without efficiency and amajor contributor is how well processes can bemeasured and controlled. Wonderware SystemPlatform will be providing Khumani mine’s managersand operators the plant intelligence they need forefficient operation far into the future.

This document was realised thanks to the support of:Johann Pienaar, Managing Director, Iritron.

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Industry: Oil & Gas

Chevron Oronite Company LLCwww.chevron.com/products/oronite/

Wonderware System Platform makes it easy to connect to an ERPapplication while monitoring the production of additives for oil and gasby Wonderware France

Goals:• To implement a SCADA system for a new additive

production unit;• To facilitate information sharing between shop

applications and the SAP ERP application;• To be able to use thin clients to connect to the

SCADA servers;• To determine standards that make it easier to reuse

and update applications.

Challenges:• Adding different types of equipment to the ERP

application;• Taking the terminology used up to this point and

standardizing it;• Meeting very short implementation deadlines;• Adopting the ISA-95 standard to define data sharing

between the shop floor and the ERP application.

Wonderware Solution:• InTouch HMI for Terminal Services;• Wonderware Equipment Operations Module;• Wonderware System Platform.

Results:• Terminology for different products and

measurement units were standardized;• Information sharing between the ERP application

and production units no longer require manualintervention;

• Launching a new product and adding new items isdone simply without jeopardizing the existingproduct;

• Through the object concept, modifications to anobject are immediately transferred to all of thegraphic displays, enabling us to save a significantamount of time compared to what was being doneuntil now.

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“We were looking for a SCADA system that would be easy toconnect to our ERP application and we also wanted to implementthe ISA-95 standard. The Wonderware System Platform meets ourexpectations. The capability to connect to thin clients and createobjects also weighed in this solution’s favor...”

Serge Talleux, Director of the industrial IT department at the Gonfreville site (France).

“We were looking for a SCADA system that would be easy toconnect to our ERP application and we also wanted to implementthe ISA-95 standard. The Wonderware System Platform meets ourexpectations. The capability to connect to thin clients and createobjects also weighed in this solution’s favor...”

Serge Talleux, Director of the industrial IT department at the Gonfreville site (France).

Gonfreville l’Orcher (Le Havre), France –Upon entering the vast chemical manufacturing sitein Gonfreville l’Orcher (France), a stone’s throwaway from the port of Le Havre, it is easy to becomedisoriented. The simplest way to maintain yourbearings in the factory of the Chevron OroniteCompany is to think of it as the Vatican! Both placeshave a similar surface area (54 hectares instead of48) and population (approximately 650 people); ofcourse, the comparison ends after thesegeographical similarities.Chevron Oronite is a subsidiary of the ChevronCorporation, one of the largest oil companies in theworld (in the United States it is second only toExxon). The company specializes in the productionof additives for fuels and lubricants. It is due in largepart to these additives that you can make it almostthe entire way across France on one tank of gas anddrive 40,000km between oil changes. A productionvolume of 300,000 tons per year makes theGonfreville l’Orcher factory one of the company’slargest manufacturing units, along with Oak Point(United States) and Singapore, which has four, moremodest sites. These three production sites are ableto manufacture all of the core products in thecompany’s portfolio (there are approximately thirty,which break down into more than 600 products).However, their primary role is to meet the needs ofthe area in which they are located (the Gonfrevillel’Orcher site basically covers the markets in Europe,Africa, and the Middle East). Each geographical areahas its own sales force and significant autonomy. This autonomy exists even when it comes to technicalchoices. However, certain decisions are made at thecorporate level, and can have a significant local impact.This is precisely what happened when corporatemanagement decided to deploy integrated ERP(Entreprise Resource Planning) managementsoftware from SAP on all of the manufacturing andcommercial sites. The objective, as it always is in this type of decision,was to improve the management and control of allof the company’s operations, costs and deadlines. Todo this, the ERP application sends manufacturingorders to the equipment concerned with thespecifications to be applied. In turn, supervisorsprovide the ERP application with manufacturingreports, raw material volumes, finished productquantities, and inventory status.

Two Simultaneous Operations: Connecting toan ERP System and Implementing a NewSCADA Application

The announcement about the implementation of anERP application was made at a time when thefactory also had to set up a new reactor. “This was alot to handle at once! We realized how beneficial an ERPapplication would be for the company; we had studiedthe entire situation, both existing applications and thenew one to be put into place. We did this all on our own.Frankly, we have always developed our own applicationsand kept up with the state of the art in technology”stated Serge Talleux, director of the industrial ITservice (seven people) in the new worksdepartment (which includes 250 people withnumerous construction trades). If the site’s onlyneed had been to connect the existing systems tothe ERP application, the problem would have beenapproached differently. In this case, however, a newcontrol application also had to be implemented,which prompted a higher, broader approach to theproblem.In terms of hardware, it was quickly decided that aprogrammable logic controller (PLC) should be usedbecause controllers were already part of thefactory’s environment, which includes sixtycontrollers managing approximately 15,000inputs/outputs.

ISA-95, a Key Advantage for the Wonderware System Platform

The remaining tasks were to choose thesupervisory control software for the newequipment and to connect all of the control systemsto the ERP application. This task was difficult giventhe factory’s previous experience in this area. A few years ago, a relatively basic ERP applicationwas installed and the industrial IT departmentdeveloped a program to enable communicationbetween control systems and this ERP application.Guillaume Labadie, who is part of Serge Talleux’steam, and more specifically involved in ERPconnection, has a bad memory of the experience:“The connection program that we had developed hadseveral thousand lines! And it only included a few of oursupervisory servers. In addition, it was a nightmare to

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InTouch HMI for Terminal Services, Wonderware EquipmentOperations Module, Wonderware System Platform.

Oil & Gas

maintain because for any new item to be manufactured(or an existing item to be modified), you had to makesome sort of change to the program... It was out of thequestion to do the same thing again because we havebetter things to do than align program lines!”

The SAP ERP application has brought with it astandard that has changed everything. This standard,the ISA-95 (known better under its former name,S95), began in the United States and is now a widelyadopted international standard (ISO/IEC 62264 andAfnor NF62264, in particular). This standard has themajor advantage of standardizing exchangesbetween the production system and the ERPapplication. “For the supervision of our new reactor, wedecided to go in a new direction and use the latest incomputer technology. More than anything, we wanted asoftware program that was compatible with ISA-95because it guaranteed the simplification of exchangesbetween the control system and the ERP application. Wewere also looking for a solution that accepts theconnection for ‘thin client’ workstations. And finally, andthis was a very important aspect, we wanted a softwareprogram that enabled us to design ‘objects’. In our eyes,there was only one solution for all of these criteria: theWonderware System Platform,” stated Serge Talleux.

A Major Project – Standardizing Terminology

To deploy the Wonderware System Platform, theChevron Oronite Gonfreville industrial IT team

began by becoming familiar with the ISA-95 standard. It consists of terminologyand models that describe both thestructural (products, materials,production facilities, and humanresources) and operational (capability,production) aspects of the productionsystems used to support informationsharing. It also defines data attributes andstructures, production operationmanagement models, and transactionsbetween management and the shop floor(ISA-95 is continuously updated and willsoon establish guidelines for storingproduction information). It is currently400 pages. “It is well-structured and detailed,but as with many new standards, it takes amajor effort to absorb it all. To better

understand it, and to ‘pick out’ what was most suitablefor our situation, our team attended a two-day trainingsession on site given by the Control Chain Group (CGC).This help was very valuable to us”, commented SergeTalleux. Implementing the ISA-95 standard involved a majoreffort to standardize internal terminology. As isoften the case on manufacturing sites with a longhistory, several different names and labels that meanthe same thing emerge over the years, and severalmeasurement units may be used to quantify oneparameter. In addition to this standardization work,routines had to be created to calculate theparameters required by the ERP application. Thus,we had to create new counters that would enableus to upload all of the consumption information thatwe need to the ERP application. A previous decisionto reduce the number of control systems installedon site (carried out by local engineering) had alreadyled the industrial IT team to undertake a similarstandardization project. Thus, having to develop ISA-95 terminology and models was not a newexperience for them. However, this work was nopicnic either, recounts Guillaume Labadie: “We knewthat it would take time, but not that much! But onceeverything is standardized, the connection between theWonderware System Platform and the ERP application isvery fast because the two databases have the samestructure. And if we want to add a new model orparameter later, it can be done immediately, nothing isaffected”.

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Figure 1: Quality test of lubrificant.

Objects and Thin Client Workstations, aBonus for the SCADA System

In choosing the Wonderware System Platform, thesimple connection with the SAP ERP application wasnot the only basis for our decision. Being able towork with thin clients was also one of our criteria;in particular, this enabled us to maintain a certainconsistency between the two systems. To accessinformation on the supervisory servers installed upto this point, the Gonfreville site is working withthin clients; in other words, very basic workstations,with no hard drive or operating system. Thisapproach has the advantage of using more robust(no moving mechanical parts) and cost-effectiveworkstations, which do not require updating.Wonderware already offered this option withWindows workstations. “We were delighted that thecompany expanded this option and that we can now useLinux workstations. In terms of update frequency andanticipated computer security, we will have a lot lesswork!” states Serge Talleux.

Redundancy was also a strong argument for choosingthe Wonderware System Platform. To ensure highdata availability, the data acquisition system nativelyintegrates a redundancy feature using simpleconfiguration. You can put some applications on oneserver and others on a second server. If one of theservers fails, the applications on the failed server areautomatically transferred to the second server.

And the supervisory feature of the platform? This isWonderware software’s strongest suit! Gonfreville’s

industrial IT department wanted to take the initiativein this area as well, as indicated by Oliver Godard,who focuses on supervision (SCADA): “We monitortechnological developments, we wanted to progress to theobject concept. Acquiring the Wonderware SystemPlatform enabled us to reach this next level. There too, wehad to challenge ourselves because the object conceptmeans a profound change in habits”. To do this,Chevron Oronite Gonfreville was able to count onskilled advice from Wonderware France, who“cautioned us against rushing forward with new softwaredevelopments, and advised us to attend training sessionfor our current products and to spend more time creatingstandards instead”. Advice followed to the letter, butwhich still created a few worries. Serge Talleuxremembers: “Normally, when we develop supervisoryapplications, we obtain the first graphic displays veryquickly. For a department director, this is reassuringbecause he sees that the work is progressing. With theobject concept, it’s better not to think about it. You waitimpatiently for months without seeing a single diagram!However, once the basic objects (valves, regulators,display devices, pumps, etc.) have been created,everything goes very quickly.” And in the long run, yousave time. It is very easy to modify both the graphicsand attributes (variables) of an existing object;modifications are immediately made on all of thedisplay diagrams containing the object in question. Infact, even a child can create these supervisorydisplays. Olivier Godard remembers a high schoolstudent on a discovery internship was able to createblock diagrams from the very first day!

Normally with SCADA applications, an effort is madeto not interfere with the procedures of the operatorsstationed in the control rooms. Here however,operators were directly involved in the improvementsmade to their control interfaces. The SCADAdesigners avoided the overuse of color on the screendisplays. Instead, they used more neutral colors (dulleven) and only used bright colors for importantinformation so that it stands out better. Major workwas also done on alarm display. Banners with endlesslists of alarms are gone, and only the alarms used forthe operator are displayed on the screen. The design of the Wonderware System Platformsupervisory system has also enabled ChevronOronite Gonfreville to turn a new corner.

This document was realized thanks to the support of:Chevron Oronite.

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Oil & Gas

Figure 2: Storage tanks.

Industry: Pharmaceuticals, Chemicals

Cambridge Reactor Design Ltd.www.crduk.com

“InTouch HMI is a ready-madesoftware solution that is easy toimplement even for complexprocesses. This is a far cry from thetraditional route of trying to writecode using complex high-levellanguages.”

Dr Bashir Harji, Managing Director, Cambridge Reactor Design

Wonderware software improves integrated high throughputsolutions and robotic platformsby Wonderware United Kingdom

Goals:• To create a homogenous machine visualization and

vision system using robotic assistants formonitoring of downstream unit operations in thechemical and pharmaceutical industries.

Challenges:• Cambridge Reactor Design had to find a way to

streamline its design process, they needed a systemthat would communicate with various control andmonitoring systems and thereby provide a solutionthat would be easier to implement, support andexpand.

Wonderware Solution:• InTouch HMI.

Results:• Using a product-based solution, Wonderware

InTouch HMI, Cambridge Reactor Design was ableto integrate many disparate devices into onesystem, reducing business risk, development andsupport costs;

• Standard solution for future applications.

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Cambridge, England – Cambridge ReactorDesign (CRD) is a producer of integrated highthroughput solutions and robotic platforms for thepharmaceutical industry and other businesses. CRDwas founded in Cambridge in 1989 with theobjective of producing customised engineeringprojects for Cambridge and other UK universities.Services were expanded to UK and Europeancompanies when CRD became a key developer ofhigh throughput technology for Shell Internationaland Avantium Technologies. Today, CRD is firmlyestablished and has a growing global customer basethat includes the Energy Research Centre of theNetherlands, Dow, ICI, Nestlé, The Royal Institutionof Great Britain, and Total.

Machine vision is a good example of combiningstate-of-the-art technology, where the latestimprovements in camera capabilities, includingmemory and resolution, offer research chemistsaccess to new analytic methods for improvingproduct quality. CRD realised new applications ofintelligent vision meant that investigations ofdownstream processing operations within thechemical industry would become more manageable.

The four most fundamental downstream processingoperations in the pharmaceutical and chemicalindustries are filtration, extraction, distillation andcrystallisation. Of these, both filtration andextraction are amenable to machine vision using theRobot Assistant system manufactured by CRD. ItsIntelligent Vision capability is made possible throughthe application of InTouch HMI (Human MachineInterface) software.

“Our basic philosophy is to make our clients’ lives aseasy as possible by offering a multidisciplinary skill-setthat deliver solutions,” says Dr Bashir Harji, CRD’sManaging Director.

A Robot Assistant for Repetitive ProcessingOperations

Robot Assistant is a mechanical organic chemistrydevice capable of performing a variety of repetitiveprocessing operations. The unit works 24x7, has aload carrying capability of 3kg, moves repeatedly andreliably to within 0.1mm, recognises motion andtakes video images. Machine vision is used in avariety of ways within the system. It captures imagesof key procedures and generates information onrate of change. The data gathered is then used forcritical real-time decision making.

A Comprehensive Solution for Integrationand Control

Wonderware InTouch HMI (Human MachineInterface) is a comprehensive solution used in theRobot Assistant. It easily integrates with all therequired input/output hardware. It offers aguaranteed method for controlling articulated robotarms and enables users to interpret theirdownstream process using a variety of graphicalrepresentations. For example, variability intemperature, time, mixing, pH control and solventsused in the downstream process can is displayedvisually with the intelligent vision elements fullyincorporated.Dr. Harji points out that the applications createdusing InTouch HMI are Federal Drug Administration

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InTouch HMI.Pharmaceuticals, Chemicals

Figure 1: Machine vision.

(FDA) compliant. It will recognise informationsupplied from the Robot Assistant’s log, and isdesigned to be tamper proof. The log is fundamentalto the system because it tracks the robot and whatit is doing at any moment in time, giving it a secureaudit trail.

Method of Working

“InTouch HMI is installed in the master computer. Theslave computers control the intelligent vision systems andanalytical sample preparation workstations,” says DrHarji. “The workstations take samples and offer theright level of dilutions so the samples are ready to beanalysed by the appropriate analytical system e.g., gaschromatography (GC) or high pressure liquidchromatography (HPLC).”

“InTouch HMI is a ready-made software solution that iseasy to implement even for complex processes. This is afar cry from the traditional route of trying to write codeusing complex high-level languages,” says Dr Harji.“Also the availability of intelligent icons to reflect theongoing performance of a real-time robotic processmakes it easy for users to interpret where they are

during the course of continual processing. All that isneeded is one Ethernet connection to the control system;one cable does it all.”

Using Wonderware software with CRD’s hardwareand machine vision application makes downstreamprocessing operations in the chemical industry moremanageable.

Wonderware software facilitated CRD’s robust andhighly innovative approach to solving difficult issuesin the chemical and pharmaceutical industries.

This document was realized thanks to the support of: Cambridge Reactor Design Ltd.

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InTouch HMI.Pharmaceuticals, Chemicals

Figure 2: InTouch HMI screen.

Figure 3: Robot in action.

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Industry: Power, Energy, General Process Manufacturing

Bodycote plcwww.bodycote.com

“Since getting Wonderware, we’venoticed a decrease in productrun-wrongs and parts that needre-processing.”

Shawn Crawford, Plant Engineer, Bodycote HIP

Wonderware Software Helps HIP Plant Profit ThroughImproved Process Control and Proactive Maintenanceby Wonderware

Goals:• Improve control and consistency of furnace

temperatures;• Enact a proactive maintenance program to save

equipment costs;• Provide better tools to increase operator efficiency

and accuracy;• Reduce product re-runs.

Challenges:• Existing data system did not provide historical

information or useful reports;• Uniformity of temperatures difficult to control

between furnace units of different sizes;• Maintenance scheduling based on calendar dates,

not run times or performance data.

Wonderware Solution: • ActiveFactory software;• InTouch HMI;• SCADAlarm software;• Wonderware System Platform.

Results:• Proactive maintenance program enabled steady

productivity and better planning of capitalexpenditures;

• Recipes have increased run-over-run productconsistency and customer satisfaction;

• Operator efficiency improved; fewer operatorsaccomplish more work with better accuracy;

• Reports provide more visibility and help facilitatebetter decision making.

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London, Ohio – No doubt, most everyone inmanufacturing today knows what it feels like to beunder intense pressure. But how about 30,000pounds per square inch (psi)? For Bodycote, a plantthat provides hot isostatic pressing (HIP), that’sbusiness as usual.

The plant processes parts for jet engines, gasturbines, automotive assemblies, medicalcomponents such as replacement joints and otheritems which must be made as strong as possible. Inthe HIP process, the parts are subjected to extremeheat and pressure, which makes them less porousand more resistant to stress fractures.

Control is Critical

At Bodycote, multiple furnace units serve the plant.Customer parts are placed in a furnace, which isfilled with argon gas. Then the unit is pressurized andheated from room temperature to approximately2,000ºF, which takes about two hours. This hightemperature is maintained throughout the process,then the furnace is cooled and the parts areremoved and inspected.

HIP quality depends on consistency and repeatability.Bodycote’s customers rely on the plant to provide auniform process, so discrete batches of productshow consistent strength and density characteristics,run after run.

Keeping the plant’s units in top condition is veryimportant. If a furnace were to malfunction,

Bodycote would be forced to re-run the batch ofparts. Worst case, Bodycote might have to replacethe parts completely, which would have a severeeffect on profitability.

Another factor is that Bodycote’s furnaces arephysically different in size. Each unit heats and coolson a unique schedule, which must be controlledcarefully in the HIP process and supervised by plantoperators.

Additionally, Bodycote has to monitor its use ofargon gas carefully. The pumps and valves on eachunit control the pressurization of the gas, which isvery expensive. So maintaining the units in goodworking condition to prevent leaks is key to savingmoney.

Strengthening the System

These challenges – providing consistent processes,maintaining the varied equipment and conservingresources – mean that Bodycote is always on thelookout for the right operations managementsoftware solutions that can help the companysucceed. The plant also needs these systems to help maintainits ISO 2001 certification.

Wonderware Cincinnati, the regional Wonderwaredistributor, worked with American Isostatic Presses,a local VAR and System Integrator, to recommendadditions to Bodycote’s data systems.

Their goals were to help Bodycoteimplement a preventativemaintenance system, get improvedvisibility to operations data andincrease operator efficiency andaccuracy.

Shawn Crawford, Bodycote PlantEngineer, appreciates the teamworkthat went into the effort, “Everyone dida great job of using the Wonderwaresoftware to produce a user-friendlysystem that’s quite outstanding.”

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Figure 1: Bodycote control room.

ActiveFactory software, InTouch HMI, SCADAlarm software,Wonderware System Platform.


A Better Way to Manage Maintenance

With the new Wonderware software, Bodycotemade a significant change to the way it schedulesmaintenance for the furnace units and supportingpumps, valves and components.

Before, the plant managers used a calendar to planupcoming maintenance. For instance, vacuum pumpswere estimated to need repair or replacementevery six months. At that time, the pump would betaken off-line for inspection, regardless of whether itexhibited any signs of wear and tear or sub-standardperformance.

But with Wonderware System Platform and InTouchHMI (Human Machine Interface), accurate real-timedata on the operation of all of Bodycote’sequipment is available. This has enabled operators tomonitor valves, pumps and other parts closely, andperform maintenance only when it’s actually needed.This not only helps the plant achieve a higher levelof productivity, but it also enables operators torepair equipment before failures can occur.

Additionally, operators can watch overall operationsfor the furnace units and other areas of the plantfrom one location. This means that fewer employeescan do more work and, because of the reliability ofthe system, they can also perform extra dutiesduring their shifts.

But real-time data is not the only advantageBodycote gets. The Wonderware Historian softwareprovides management with the historical data they

need to extrapolate furnace life and better plan forfuture capital expenditures. Because millions ofdollars worth of equipment are required for the HIPplant, this is extremely important.

Superior Process, Superior Product

Before adding Wonderware software, Bodycote’soperators used ‘touch and feel’ to regulate power tothe furnaces and maintain consistent temperatures.With the different furnace sizes and other variablesin the environment, even the most experiencedoperators were put to the test.

With the new system, recipes for repeated batchesare programmed into the Wonderware software.This has improved consistency over multiple runs,and has increased customer satisfaction. When acustomer has a question, it can be answered quicklyand in detail, thanks to the new reportingcapabilities. The reports can prove adherence to arecipe, or can pinpoint the exact time andparameters of a change in the process.

The need to re-process parts due to temperaturefluctuation or operator error has been nearlyeliminated, and Wonderware SCADAlarm™software alerts operators to equipment that needsattention, or triggers an automatic shutdown if apre-determined threshold is exceeded.

Best Feature: User Interface

When asked, Crawford is quick to point out that themost important feature of the new Wonderwaresoftware solution has been its usability. He says thateveryone in the plant enjoys working with it.Diagrams and on-screen icons representingequipment, configurations and recipes are easy tosee clearly and quickly understandable. He pointsout that there are many different screens, but not somany as to confuse operators – even less-experienced ones.

As a matter of fact, Bodycote plans to use theWonderware software for training. Example runsand problem situations can be simulated so that

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Figure 2: InTouch HMI screen showing manufacturing process.



operators can learn how to best react. And theseexercises can be accomplished without taking theplant systems offline, so there’s no impact onproductivity.

Versatility under Pressure

The Wonderware software has brought Bodycotethe stability and repeatability required to turn outconsistent products for its customers. It hasimproved preventative maintenance and the abilityto cut costs for resources such argon gas as well asreduce expenses due to production errors. And notonly that, the new solution has been popular withmanagement and operators alike.

Crawford feels that Bodycote has just scratched thesurface of the Wonderware software’s capabilities.He hopes to implement new ideas he has beendeveloping for utilizing data and reports foradditional efficiencies and savings. The versatility ofthe solution and the resourcefulness inherent inBodycote should enable the plant to continue towithstand market pressures – and succeed – forquite some time.

This document was realized thanks to the support of: Wonderware Cincinnati.

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Figure 3: Bodycote plant floor showing control of kiln.



Industry: Power, Energy

Eskom Holdings Limitedwww.eskom.co.za

“Through the Wonderware solution platform and ArchestrA technology, the PDS system has succeeded in bringing the plant automationand information technology worlds withingeneration together.”

John Viljoen, Corporate Consultant for Generation Business Engineering, Eskom

Eskom’s PDS project is helping the company see the light!by Wonderware Southern Africa

Goals: • To merge the plant information world with the

company’s information technology environment;• To turn plant data into useful information that

would be openly available;• Improved performance indication;• Improved incident response.

Challenges: • Structuring a data model in compliance with

Eskom’s Generic Plant Breakdown Guide and theISA-95 standard;

• Conforming to Eskom’s structure adjustments halfway through the project.


Results: • Real-time plant data;• Standardization facilitated the reduction of

engineering effort, rapid adaptability to changes andelimination of disparate information solutions;

• Significantly highlighting the benefits that can bederived from open access to real-time and usefulplant information;

• Closer relationship between plant and IT and thedifferent needs of both disciplines;

• Numerous applications are now using the PDS dataand all the information is available anywhere to anyqualified person;

• PDS is a business enabler that improves the abilityof people to conduct their business moreeffectively.

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Johannesburg, South Africa - Eskom HoldingsLimited is a vertically-integrated operation thatgenerates, transmits and distributes 95% of theelectricity used in South Africa. The company isamong the top seven utilities in the world in termsof generation capacity and among the top nine interms of sales.

Eskom Enterprises, the wholly-owned subsidiary ofEskom, together with its subsidiaries, serves as ameans by which all the non-regulated activities ofEskom, both inside and outside South Africa, arecarried out. Eskom Enterprises’ core lines ofbusiness are infrastructure development, energybusiness operations, specialised energy services andthe pursuit of key opportunities in related orstrategic businesses, such as information technologyand telecommunications.

The operations of Eskom are located in South Africa.Eskom Enterprises has operations on the Africancontinent, with its head office being located inJohannesburg, South Africa and other offices inUganda, Nigeria and Mali.

Oil and electricity are the 21st century’s energy hotpotatoes. At the start of 2008, South Africans had asmall taste of what life without electrical energywould be like - intolerable. That’s why Eskom isinvesting a great deal of energy, finance andtechnology into understanding the behavior andstatus of its complex grid and generation facilities on

a national level with an initiative that is known as thePlant Data System or PDS.

Background - Plant Information Issues

“The drive for increased reliability and efficiency ofoperation requires better plant information in real time,”says John Viljoen, Corporate Consultant forGeneration Business Engineering at Eskom. “Theplant condition is deteriorating due to ageing whichprompts the need to get a better handle on conditionmonitoring information and since electricity supply mustmatch the demand at all times, accurate productioninformation is critical.”

Traditionally, process automation solutions provideoperating information to help operators managetheir plants more effectively but, according toViljoen, this is only one aspect of the informationspectrum necessary for Eskom to be more effective.“Engineers, for example need asset information for assetlifecycle management. It’s not as if we lack the data, wehave masses of it at plant level but useable informationis not readily accessible.”

Information Technology Issues

While Eskom’s IT infrastructure focuses onimproved business performance and efficiency, it isnevertheless a transactional environment not suitedto the real-time world of plant production. “As far as

IT is concerned, plant control systemsare black boxes that we don’tunderstand,” says Vicki Naudé,Senior Advisor for GenerationInformation Management at Eskom.“Our integration and storage methodsfocus on transactional systems in afragmented and outsourced ITinfrastructure that isn’t suitable for thereal-time plant environment. So theintention is to broaden the scope of ITto include plant information whileproviding for the necessary levels ofsecurity.”

This left Eskom with the challengeof managing the escalatingcomplexity of merging its plant

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InTouch HMI, Wonderware System Platform.Power

Figure 1: Eskom’s “shop floor”. Each of the coal-fired units typically consists of a boiler and a 600MW generator - although this can vary.

information world with its information technologyenvironment.

Project Objective

The Plant Data System project goal is to make plantdata openly accessible, in a standardised format, toevery area of the business that can use it to improvethe bottom line. In order to do this, plant datawould have to be readily transformed into usefulplant information in order to meet the specificinformation needs of personnel at different levels.

Hopefully the more effective use of plantinformation would have ultimately resulted in morerefined performance indicators, better plantoptimisation and better resource allocation. Plantdata could also be delivered to specialist engineersin order to improve incident response.


Any solution must meet the need of real timeinformation to support both operational andbusiness decisions while also addressing the issue ofstandardisation. “Each power station is unique and inthe past, there had been no attempt at standardisationso that they all had different control and operationalsystems,” says Viljoen. “Since the natural tendency is forpeople to improve their information systems, we didn’twant a proliferation of different solutions with each

power station implementing their own ideas. So, aprimary requirement was standardisation that wouldeliminate duplication of engineering effort, interfacedevelopment, solution deployment, etc.” Eskom wouldselect a solution based on the least cost but thatwould provide the required functionality. “Such arequirement would indicate a centralised solution ratherthan the far more expensive alternative of multiple anddiverse information systems,” adds Viljoen. “Anotheradvantage of basing solution selection on cost is that oneof the major cost components of such systems islicensing, which is based on tag volume. By purchasinghalf a million tags for the whole of Eskom, we spentsignificantly less than if each power station bought, say50 000 tags of its own. So, according to our structure,buying technology that would meet these requirementswas seen as establishing a platform enabling the variousparts of the business to improve their performance. Inother words, we have installed a business enabler.”

Solution Selection

Eskom issued an open Request For Proposal to themarket and the Wonderware solution was deemedto offer the best cost / functional performance ratio. The ArchestrA framework was ideally suited to therapid deployment of a standardised solution acrossall the power stations and web based viewingenabled a cost effective method of managing a largenumber of simultaneous users. The combination ofWonderware System Platform, WonderwareHistorian, InTouch HMI (Human Machine Interface)and the Wonderware Information Server met all thespecific requirements for real-time datamanagement. Eskom selected ArchestrA-certifiedsystem integrator Bytes Technology Group becauseof the company’s track record of implementing largeand small PDS-like solutions on-time and in budget,its existing knowledge of Eskom solutions and itsnumerous awards for the successful implementationof integrated ArchestrA-based Wonderwaresolutions.

Plant Data System Project Description

With the project goal of providing a standardplatform in order to obtain Generation plant data

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Figure 2: Topology diagram showing the relationship between headoffice (Megawatt Park) and power stations – only the Matla powerstation is shown here.

via a single interface, Eskom structured the systemas shown by the topology diagram in figure 2 (onlyMatla Power Station shown). “While each powerstation has its own Historian, we replicate theinformation we need at head office in a central Historianso as to minimise WAN access,” says Naudé. “We alsohave a firewall between the business LAN and theprocess LAN for security purposes and to ensure thatonly the PDS has access to process data.”

Eskom spent a lot of time and effort to structurethe data model so that it would conform withEskom’s Generic Plant Breakdown Guide and theISA-95 standard, an exercise which would soonprove to be extremely worthwhile. “Halfway throughthe project, Eskom changed its structure and we hadalready built our (Wonderwre System Platform /ArchestrA) galaxy,” says Naudé. “Instead of a trainsmash, we were confronted with a simple drag-and-dropexercise before once again being on track. This could nothave happened without a properly designed datamodel.”The design of master templates for such plant itemsas furnaces also greatly reduced engineering timeand facilitated deployment since only specificattributes needed be changed to cater for differentfurnace types. The initial target for the PDS is 80 super users(ActiveFactory software) and 500 web users. Sincethe generic training on the Wonderwarecomponents of the PDS would take approximatelysix weeks with the risk of users losing interest along

the way, Wonderware Southern Africastructured a condensed three-daytraining course specific to the PDS.Since it was deployed, the PDS hasbeen of such value that users havewanted more and motivated for theexpansion of this valuable informationcommodity. Although the PDS is onlypart of Eskom’s overall informationstrategy, it is nonetheless the real-timeportion that provides decision makersa vital window into the realities oftheir power generation initiatives.

Realised Benefits

• Real-time plant data is now a reality and availableto anyone who can make best use of it;• Standardisation facilitated the reduction ofengineering effort, rapid adaptability to changes andelimination of disparate information solutions;• The approach taken towards the PDS project wasdefinitely cost effective and proved the economiesof scale that can be achieved with the right solution;• The PDS project has significantly raised thevisibility of the benefits that can be derived fromopen access to real-time and useful plantinformation;• The project has fostered a closer relationshipbetween plant and IT and the different needs ofboth disciplines;• Numerous applications are now using the PDSdata and all the information is available anywhere toany qualified person;• PDS is a business enabler that improves the abilityof people to conduct their business more effectively.

Conclusion

Eskom bears an awesome responsibility – thecontinuation of our way of life - while its ‘shop floor’consists of nothing less than Southern Africa. Eskomnow has the tools to understand and control its vastand complex power generation machine and toimprove the quality of life of more than 50 millionpeople.

This document was realized thanks to the support of: Vicki Naude and John Viljoen, Eskom.

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Figure 3: ActiveFactory software screen showing a typical 7-day load profile at LethaboPower Station.

Industry: Power, Energy

S.T.E. Energy S.p.A.www.ste-energy.com

Different Plants, Single Control Centralized management and control over intake works andhydroelectric dams enable reduced costs, increased efficiencyand optimized productionby Wonderware Italy

Goals:• Ensure quality, performance and efficiency of

hydropower plants.

Challenges:• Environmentally friendly plants;• Minimized operating costs.

Wonderware Solution:• ActiveFactory software; • InTouch HMI;• Wonderware System Platform.

Results:• Maximized energy generation;• Reduced maintenance costs thanks to preventive

and scheduled maintenance.

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“In order to build a unique and highly effectiveplant, we chose to collaborate withWonderware, a specialist with high expertisein this sector, delivering products able tointegrate innovation and ease of use.”

Mario Arquilla, President and Managing Director, STE Energy

Padua, Italy –With more than two hundredsystems implemented over the past years in Italyand abroad, and with its branch offices located invarious countries, STE Energy today is one of themajor operators in the field of energy and plantengineering.

STE Energy was established in 1995 in Padua, Italy. Itdevelops, designs, builds and manages energyproduction plants, especially the hydropower typeand electrical and thermotechnical systems, as ageneral contractor. It also builds wind, solar andbiomass cogeneration systems and electric energyproduction, transport and distribution plants allaround the world.

Quality, performance and efficiency are the keyfactors in energy generation. Companies in thismarket constantly seek for solutions enabling tooptimize production, by leveraging the latesttechnologies on the market and always keepingenvironmental issues into consideration.In this scenario, traditional hydropower plants, whichin recent times were neglected in favour ofapparently more efficient methodologies, are back inuse and now developed according to innovativeprinciples. STE Energy, based in Padua, specializes inthis activity and deploys innovative hydropowerplants on a global scale.

“In order to be competitive on the international market,”explains Mario Arquilla, President and CEO, STEEnergy, “it is necessary to offer solutions enabling tooptimize the whole production process, providingmeasurable and demonstrable results. For this reason wechose to apply modern automation technologies even tohydropower plants, especially for production control andmonitoring.”

Leveraging Every Single Drop

Traditional hydropower plants were based on bigdams having high environmental impact and effectiveonly if deployed on high discharge rivers. On thecontrary, the current vision prefers run-of-riverpower stations, able to leverage even the smallestdrops. This way it is possible to reduce developmenttimes, minimize environmental impact and, most ofall, ensure high efficiency levels. The sum of theenergy produced by different dams in succession ishigher than the one produced by a single big plant.Power companys need to take into accountadministation costs in their total budget. Havingdedicated operators in every single plant impliesconsiderable costs, contrasting with the need tominimize expenses. Furthermore, some plants aresituated in almost unreachable places, and determinehigh costs for moving operators.

In the light of suchrequirements, STEEnergy engineers choseto leverage a similarcontrol technology asin the field of industrialautomation: collectingall data locally from thedifferent power plantsand centralizing them ina single control point,where activities areautomatically managedand supervised byspecialized engineers. ‘Telemetry logic’, explainsArquilla, “providesproducers with a highlyefficient control system,delivering real-time

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ActiveFactory, InTouch HMI, Wonderware System Platform.Power, Energy

Figure 1: Inside hydropower view with a close-up of the alternator.

operating data of every single component in thehydropower plants. In this way engineers can interveneaccurately and timely to solve problems, avoidingunuseful interventions and optimizing activities. Thisopportunity is particularly useful in daily managementand allows to optimize operator activities. In order todifferentiate from the competition, we were seekinginnovative technologies to provide our customers with areal competitive advantage. Finally, we evaluated thebenefits offered by the MES technology, knowing thatonly a perfect knowledge of production processes couldallow us to optimize our activity”.

STE Energy chose to collaborate with Wonderware,market leader in real-time operations managementsoftware. “In order to build a unique and highly effectiveplant,” continues Arquilla, “we chose to collaborate withWonderware, a specialist with high expertise in thissector, delivering products able to integrate innovationand ease of use.”

Preventing Failures

The choice of investing in such an innovativetechnology is determined by the fact that STEEnergy also takes care of maintenance activities.Perfect maintenance of power infrastructures, whichneed to work without interruptions, requires highcompetence levels both in practical activities, and inpreventive actions. Operating only upon customers’

request, in fact, means always working in‘emergency’ conditions, since interruptionsin power production cause loss of income.STE Energy therefore chose to implementpreventive and scheduled maintenance: “asimilar method,” explains Arquilla, “has beenadopted in the most innovative manufacturingcompanies and this is why we chose to applyit to our market.”

All data collected in the control rooms ofthe single plants are sent to STE Energyheadquarters in Padua and saved in realtime in the Wonderware Historiandatabase, then constantly monitoredthrough specific Wonderware applications. These smart solutions enable toimmediatley detect any decrease inperformance and the presence of unusualconditions thanks to cross-comparisons of

data. “In the most banal of cases,” continues Arquilla,“on equal discharge dams present a reduction in powergeneration. In this case, the supervisory system, whichwas programmed to optimize system efficiency, sends analarm notification. The engineers can analyze the singlevalues collected by the local monitoring systems thanksto the extremely intuitive graphic capabilities based onthe HMI and SCADA systems, we developed byleveraging Wonderware InTouch HMI capabilities.”

This operating method allows STE Energy toundertake preventive actions, so that STE Energyexperts are able to notify to local engineers thepresence of unusual conditions, also indicatingsuitable intervention to restore the optimalsituation.

Simple One Click Historization

All data which are collected and stored byWonderware Historian allow you to know all thestatistical and analytic data of specific streams anddams.

Wonderware solutions allow to leverage such ahuge amount of data in the best possible way, inorder to optimize production activities. It is possibleto know a river’s dispatch throughout the year,according to specific weather and environmental

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Figure 2: Plant synoptic of teh turbine - generator group.

conditions, in order to plan specific maintenanceactivities and to satisfy the demand in the differentperiods of the year.

Furthermore, engineers are constantly informedabout the amount of electricity produced accordingto weather and environmental conditions and theevents that occurred with time. It is possible toimmediately detect inefficiency causes, distinguishingproblems connected with different kinds of failures.

Always connected

Leveraging industrial technologies for civil andgeographically distributed works determined theneed to exploit all the available telecommunicationstechnologies. Data collected in the single dams mustin fact be sent to the control room in real-time. Andthis could be a complex task, especially if there areno telecommunications networks. From thisstandpoint, Wonderware integrated solutions arethe best solution to interface with anycommunications technology. This means that, in case there is no traditionaltelephone network, data can be exchanged viamobile phones, satellite or radiofrequencycommunications, thanks to the scalability ofWonderware management systems which, at anearly stage, had been implemented only in the newplants. This way the project could start with low

initial investment and pilot functions, thenprogressively expanding the control systemaccording to the excellent results that wereobtained.

The constant monitoring of the activities in thehydroelectric plants enabled to optimize theefficiency, but also delivered an useful tool for theoperators in the different control rooms.

Operators are constantly informed aboutperformance and real-time production of the singlepower plants, thanks to common handheldcomputers, with the possibility to analyze singlevalues and historical data in detail.

Energy looking into the future

The availability of such an amount of data, which areautomatically and efficiently processed, enabled STEEnergy engineers to improve projects for newpower plants. In the development stage, engineerscan leverage a database containing all the datacoming from dozens of plants on a global scale. “Theinformation, processed by Wonderware analysis tools,enables to understand the factors which allowmaximizing efficiency and reducing maintenance costs –with the purpose of progressively improving plants,making them more and more efficient and reliable,”concludes President Arquilla.

This document was realized thanks to the support of: STE Energy S.p.A.

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Industry: Process Engineering

Meteng Pty Ltd.www.meteng.com.au

“We found enormous differences in data transfer andoperator response rates with other systems, but we havenot yet found any limitation on what we can do withWonderware software.”Jim Groutsch, Managing Director, Meteng Pty Ltd

Wonderware and Meteng Combine for Innovative 3DProcess Modeling and Simulation Systemby Wonderware Australia

Goals:• Enable an accelerated design process so that plants

can begin to generate income more quickly;• Provide an interactive simulation environment that

saves time and money by testing plants andprocesses before they are constructed;

• Facilitate more effective learning by enablingoperators to make mistakes and practiceresponding to emergency or out-of-complianceconditions without negative consequences.

Challenges: • The complex Walk-Through Interactive Simulated

Environment (WISE) system has enormous powerrequirements and integrates Apple, Windows andWonderware technology with very large, high-resolution displays;

• The system had to be built with components thatwould ensure easy and cost effective expansion tomeet the needs of many different clients.

Wonderware Solution: • InTouch HMI;• InControl software.

Results:• Improved system performance. Increased data

transfer rates and response to operatorinteractions on the various systems that make upthe simulation system;

• Software platform enabled development offunctionality Meteng required for its simulationsystems;

• Developers could concentrate on task of processmodeling and simulation instead of focusing oncomplex program code;

• Software offered opportunity for Meteng todevelop methods enabling re-use andstandardization, resulting in tremendous savings inengineering costs.

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Brisbane, Australia – Imagine a realistic tour of aminerals processing plant that has not yet been built,where you can not only see the entire facility, butalso adjust the valves, read the meters, walk up anddown stairways and even practice responding to afire or explosion. If this sounds like a video game,it’s meant to. And it’s also an inventive new way tosave plant design costs and safely train operators forreal-world scenarios.

Brisbane is known for its natural resources,especially metals and minerals, and Australia’s miningindustry is concentrated in the region. So it’s a nosurprise that Meteng Pty Ltd, an engineeringconsultancy specializing in process modeling andsimulation, would have expertise and customers inthis segment. What may not be as expected is thatthe firm would take such a novel approach.

Technology That Capitalizes on HumanNature

Meteng started by studying cognitive science andlearning. Research shows that humans havetremendous ability to process and analyze massiveamounts of data, and that we retain knowledge bestin interactive training, when we experience theresults of our actions. Therefore, people discoverhow to make better decisions when they canpractice scenarios and make mistakes withoutnegative consequence. Some call it ‘learning by doing’.

Meteng translates this to the engineering world. Thefirm’s goal is to help their customers plan and designplants more efficiently, maximizing the value of their

physical assets and their people, so they can increaseprofits, empower employees and enjoy sustainablegrowth and success.

The result is the WISE system, or Walk-ThroughInteractive Simulated Environment. Using powerfulcomputers to process dynamic mathematical datamodels along with several large, high-resolutionscreens, WISE is a 3D spatial experiences set in a‘cave’ with surround sound. It is like being within avideo game, but rather than an imaginary setting,WISE simulates an actual processing plant, includinga prototype SCADA and control system.

It’s No Worries with Wonderware

As Meteng brought the WISE system to life, a majorconcern was that its complex processingrequirements would cause performance orfunctionality roadblocks. But when WonderwareAustralia, the local Wonderware distributorintroduced Wonderware software to Meteng, theyfound an easy-to-configure solution that met theirneeds and enabled the firm to develop uniquesolutions.

While the main requirement was high performancewith functionality, ease of installation and updatesplus excellent technical support were other factorsin the decision to integrate Wonderware softwareinto the sophisticated system. Wonderware software serves as the main controlcenter, opening the 3D models, loading dynamicprocesses, and initiating or saving training scenarios.Specifically, Wonderware InTouch HMI (Human

Machine Interface) adds a versatile,intuitive GUI for the WISE SCADAsystem, while Wonderware InControlsoftware provides easy-to-integrate,expandable control and scripting thatsupports the system’s interlocks andlogic control.

Meteng applies its processengineering skills when it comes toanalyzing workflow and developingefficient processes. Wonderwaresoftware supports them with its

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InTouch HMI, InControl software.Process Engineering

Figure 1: Meteng 3D Process Modeling and Simulation System.

powerful standardization and repeatabilitycapabilities. Groutsch says, “Once a module isdesigned, it’s easy to rapidly spin off other versions andtailor them to specific operator and plant requirements.It helps us to be smart and efficient, plus we can do it ata fraction of the cost.”

Changes and re-work to control systems andgraphics are also facilitated smoothly. Meteng canrespond quickly to client comments and requestsfor revisions. And when clients are participating inthe continuous development of their plant, they areactually seeing the Wonderware software at work intheir environment.

Wonderware has also been a capable partner forsupport. Groutsch is complementary of theassociation formed between Meteng, Martin Halsey

and the Wonderware Australia team. He elaborates,“The best thing about it is that the software is sotrouble-free, the need for support almost doesn’t exist!”

The Key is ROI

Meteng has grown up in the mining and mineralsprocessing industry, but as these plants have becomemore complex, they have incorporated simulationsfor power stations and chemical plants. They believethe application of the WISE system to newtechnologies, such as renewable energy processesand carbon reduction projects can significantly helpovercome problems in getting new technologies offthe ground.

But no matter what the segment, return oninvestment is critical – for Meteng and theircustomers.

Since it can cost up to ten times more to fix adesign problem onsite than when it is solved insimulation, and since programming errors that delayproduction can cost millions of dollars, the Metengsolution is proving its worth to the firm’s customers.

Meanwhile, Wonderware software continues tomake solid contributions to Meteng’s high-performance system. Groutsch says it best, “It allowsus to do what we want, and do it well.”

This document was realized thanks to the support of: Meteng Pty.

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InTouch HMI, InControl software.Process Engineering

Figure 2: Meteng interactive screen.

Take the Wonderware andwatch efficiency take off.

The powerful and openWonderware System Platform software has enabled the largestecosystem of system integrators and third-party providers in the industry to deliver solutionsthat help their customers’ businesses with faster, real-time collaboration and decision support.

Over 3,000 SI organizations around the world are leveraging the power and ease ofWonderware in record time, while helping their customers achieve operational success.

Put some POW into your operation. GetWonderware. www.wonderware.com


T H A N K S T O

PowerfulOpenWonderware

Industry: Pulp & Paper

Lenzing AGwww.lenzing.com

“The performanceof the facility was

doubled – and that is a success.”

Harald Schlader, System Administrator

and Product Coordinator, Lenzing

Modern Automation Technology for a Cellulose FiberManufacturing Plantby Wonderware Austria

Goals:• Efficient production;• Increase production capacity;• Seamless flow of information;• Reliable production technology.

Challenges:• Modernization of production automation system.

Wonderware Solution:• ActiveFactory software;• InTouch HMI;• InTouch HMI for Terminal Services;• Wonderware System Platform.

Results:• Increased efficiency;• Higher productivity.

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Lenzing, Germany – The Lenzing Group, based inthe Austrian city of Lenzing, is successful worldwidein the international Textile and Non-Woven marketfor the past decades. Lenzing today is market leaderin many Business-to-Business markets: from specialcellulose fibers to high-quality plastic-polymers.

To produce effectively in a high wage country likeAustria, it is only obvious that state-of-the-artmanufacturing plants are the keys to profitability.Seamless flow-of-information and digitalizedproduction management are as fundamental toLenzing engineers as functional tools for diagnosis,data collection and archiving. They rely on efficienthardware as the basis for automation architectures,and combine that with software products specificallymodified for the different production divisions. Thiswas also the case during the modernization of anexisting cellulose fiber manufacturing plant, whereperfectly integrated Wonderware software solutionsallowed for a considerable increase in efficiency anda consequent boost in productivity.

Looking back on 70 years of experience in the fiberproduction, the Lenzing Group is the onlymanufacturer worldwide with expertise in all threegenerations of the so-called ‘man-made cellulosefibers’ - from classic viscose to modal- and lyocell-fibers. Lenzing’s success is based on consistentcustomer-orientation combined with leadership ininnovation, technology and quality.

Next to the core business in fiber and syntheticmaterial, Lenzing is also experienced in machinebuilding and engineering. A high level of automationensures an efficient production, in which thecompany invests continuously.

In order to update the automation system and adaptthe production capacity to an increased level ofincoming production orders, the existing hardware(Simatic S5) was replaced by more efficient SimaticS7 CPUs. Also, the automation system was to beintegrated into the production area and to allowremote diagnosis.

“In the past, our production assistants had to be on siteto collect data from meters and to manually put thedata into the production database,” says HaraldSchlader, Lenzing System Administrator. “Also, theelectrical staff had to be on-site to evaluate a problem.Remote diagnosis was not possible.” SinceWonderware InTouch HMI (Human MachineInterface) software has been used for thevisualization of the cellulose fiber production areafor approximately 10 years and a large, continuouslygrown, object-library already existed, it was decidedto put the modernization of the production areainto the hands of Wonderware. “Our experience withInTouch HMI is very positive. Especially InTouch HMI forTerminal Services software has proven to be perfect forus,” mentions Harald Schlader with reference to theadvantages of the visualization system.

Automation Solution Structure

Due to the unrivalled openness of theWonderware software, regular PCsrunning with Windows XP operatingsystem can be used as user stations in thecontrol room. They are automaticallyconnected to the Terminal Servers in thedistribution room with InTouch HMI forTerminal Services. Based on the ArchestrAtechnology, this technology provides theuser with a unified environment in whichthe information coming from different datasources can be integrated.

The environment offers a commoninfrastructure plus a unified set of services.

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ActiveFactory software, InTouch HMI, InTouch HMI forTerminal Services, Wonderware System Platform.

Pulp & Paper

Figure 1: Thanks to the deployment of InTouch HMI, now production assistants inLenzing can optimize production processes directly from their offices.

Lenzing also standardized the use of theWonderware Historian as a production database. Itis based on Microsoft SQL Server and allows accessto real-time information for the analysis of plant andequipment data. The complete production data areautomatically collected from various data sources,e.g. industrial OPC-Server or one of the +600different I/O Servers. Lenzing also uses theWonderware Historian to export production datainto a higher-level ERP System.

For data trending, analysis and reporting,Lenzing chose Wonderware ActiveFactorysoftware. This software offers tools for anoptimal utilization of data stored in theWonderware Historian. Functional point-and-click dialog boxes facilitate theretrieval of production and process dataand simplify troubleshooting, in case ofpotential process inefficiencies, eliminatingtime consuming error localization.

With DASSIDirect, Lenzing takesadvantage of the powerful WonderwareDAServer for the communication withSimatic S7 PLCs based on TCIP/IP. Acustomized ‘SFC Wizard’ enables theautomated import of up-to-dateinformation from the ‘S7-Graph’ from

Siemens into InTouch HMI. Otherwise thedisplay of current information would nothave been possible.

Advantages & Benefits of theWonderware Solution

InTouch HMI for Terminal Services wasmainly chosen because of the long distancebetween the cellulose fibers productionarea and the rest of the production plant.

The maintenance staff can now solveminor problems directly from theirworkstations. And production assistantscan now carry out certain productionprocess optimization activities directly attheir PC.

“Since InTouch HMI is Windows-based andWindows is our standard operating system, PCs in theproduction area can be maintained by our internal ITdepartment,” states Harald Schlader. “Also, InTouchHMI gives us full flexibility regarding the choice of server- unlike other Terminal Server Solutions suppliers. Theopen OPC interface of the I/O Server is anotheradvantage.”

The implementation of the InTouch HMI applicationwas short and smooth, thanks to the vast

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Pulp & Paper

Figure 2: Total transparency: with the perfectly integrated Wonderware softwaresolutions Lenzing obtained considerable increases in efficiency and therefore higherproductivity in the cellulose fiber production.

Figure 3: Thanks to the InTouch HMI for Terminal Services, all process parameters canbe easily visualized and customized with simple mouse click from standard office PCs.

experience of the Lenzing engineers, but also thereusability of the SmartSymbols’ Library: theSmartSymbol technology allows the reusability ofgraphic templates. Object-oriented graphics includegraphic-, script- and tag management tools,necessary for the appropriate use of applicationobjects in a production environment.

New applications are created based onstandards, that way ensuring thecompliance with company procedures.Existing applications can easily be adjustedby changing the SmartSymbol template.

“We gradually enlarged and improved ourlibrary to make sure that the integration ofnew equipment is done as fast as possible. TheSmartSymbols we used had to be changedonly a little to fit the individual processes,”says Harald Schlader. He also complimentsWonderware Support: “The supportagreement with Wonderware provides acontinuous software upgrade of our software.The technical helpline staff is competent,quick and is of a great help.”

All-in-all, the Lenzing Group realized a vastimprovement regarding product-control andmaterial usage thanks to the use of InTouch HMI forthe production of special cellulose fibers. “Wedoubled equipment performance – and this is a prettybig success,” concludes Harald Schlader.

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Figure 4: A proprietary SFC Wizard providing the automatic import of Data inInTouch HMI is deployed for the visualization of actual information of Siemens S7Graph. Without this software, a specific application for the visualization of real-timestatuses would have been necessary.

This document was realized with the support of:Harald Schlader, System Administrator and Product Coordinator, Lenzing.

Industry: Transportation

Tecnositaf S.p.A.www.tecnositaf.it

“We invested in thedeployment of the mostmodern safety systemsavailable on the markettoday, developing solutionsenabling us to go farbeyond internationalstandards.”

Giuseppe Celia Magno, Sales and Quality Manager, Tecnositaf S.p.A.

SCADA: an Important Help for Managing the RoadInfrastructureby Wonderware Italy

Goals:• Ensure the highest safety levels through the

deployment of maintenance and infrastructuremanagement systems.

Challenges:• Limit maintenance costs while ensuring maximum

safety.

Wonderware Solution:• ActiveFactory software; • InTouch HMI;• InTouch HMI for Terminal Services;• Wonderware System Platform.

Results:• Reduced maintenance and energy consumption of

the tunnel lighting and venting systems;• Deployment of a fire-fighting system meeting

highest safety standards.

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Bussoleno (TO), Italy –Tecnositaf, an integratedengineering company founded in 2001, is a SITAFS.p.A. company (A32 motorway, Torino –Bardonecchia and Fréjus Tunnel operator) thatdesigns, develops and manages systems and tools forthe mobility control and road (urban and extra-urban, outdoors and in tunnels), rail and industrialsafety.

An Experience Along A32 Torino –Bardonecchia Motorway

Wonderware and Tecnositaf experience andtechnologies have been put together to ensuremaximum safety along the whole A32 Torino –Bardonecchia motorway infrastructure.Everyone of us, when driving on a motorway, isespecially concerned about traffic and roadconditions. But actually our safety depends onalmost invisible technological infrastructures, whichneed to be perfectly working.

Managers of big infrastructure networks are fullyaware of this issue and, in recent years, have beeninvesting in strengthening those systems, providingthem with the most efficient management andcontrol tools. Maintenance and management of theroad infrastructure, in fact, are not only the maingoals, but also the highest costs for the contractor.Highways must be always open and ensure constantsafety levels; any maintenance intervention involvesorganizational challenges and the need to openbuilding sites, causing dangerous road narrowings.In order to improve service levels, ensure safety andlimit maintenance costs through an exact scheduling,

SITAF (Società Italiana Traforo Autostradale delFréjus), as contractor of A32 Torino – Bardonecchiamotorway, recently invested in the expansion of thetechnological infrastructure ensuring the safety ofthis major road connecting Italy to France. Thischoice has been also influenced by the fact that 18of the total 73Km are tunnels, a potentiallyhazardous environment for vehicles and the placewhere rescue interventions are really difficult, astestified by recent dramatic news.

Tecnositaf (specialized in integrated systems forroad safety) has been therefore involved in thisproject, due to the expertise of its collaborators andthe experience with other companies managingstreet and motorway systems.

Air Quality Control

“In the light of this,” as explained by Giuseppe CeliaMagno, Sales and Quality Manager, Tecnositaf, “weinvested in the deployment of the most modern safetysystems available on the market today, developingsolutions enabling us to go far beyond internationalstandards.”

In such a project, constant event monitoring andautomatized management systems are key factorsprovided thanks to the collaboration withWonderware System Platform, combined withInTouch HMI (Human Machine Interface),represented the ideal solution for supervising thewhole road section. This solution is among the mostinnovative on a global scale, since it leaves thefreedom of customizing the application in order todevelop all necessary controls Sitaf aimed at, and toreach the integration level Tecnositaf expected, allthe while providing a reliable solution.

The project, personally followed by AndreaBallatore, Wonderware certified system designer,aimed at replacing the pre-existent and out-of-dateSCADA system, using the most efficient controltechnologies, especially for tunnel ventilation.Inside highway tunnels, under particular weather ortraffic conditions, there could be a highconcentration in exhaust gases, affecting visibilityand, in the severest of cases, the health ofpassengers. These are the reasons why the venting

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Figure 1: Central control headquarters A32 motorway.

system must ensure suitable air makeup. Non-stopventilation implies high energy consumption, alongwith rapid deterioration of fans, and makes periodicand expensive maintenance necessary.

Manual management proved demanding andinefficient, mainly because personnell operatinglocally cannot have full visibility into the completesystem. Gas concentration is not only influenced bytraffic and passage of trucks or highly pollutingvehicles, but also by external factors, such asweather conditions at the entrance end exit of thetunnel. It is possible to foresee almost exact trafficconditions in some timeframes, allowing to set theventing system up according to forecasts.

Wonderware solution has been customized tointeract with 86 PLCs controlling the single localplants which are based on a master/slave logic andable to work autonomously, according to theinformation retrieved from field devices andhistorical archived data.

An optical fiber 1Gb/s network, 73Km long andsuitably backed up, allows centralizing all theinformation in the central control room in Susa,where all emergency actions are coordinated. CO2concentration monitoring is ensured by sensorswhich start only the necessary fans in thelongitudinal venting system, at the required speed, incase the concentration exceeds preset values.

Furthermore, according to the naturalspeed of the airflow detected by theanemometers installed at the entranceand inside the tunnels, the system sets thenumber of fans which would be enough tokeep the air in tunnels always fresh.

This management system drasticallyreduced maintenance, extending theoperating life of mechanical systems and,most of all, reducing electricity costs.

All the Light Needed

Tunnels are critical passages in everytravel. In case of sudden lighting changes,human eyes require more then onesecond – the so-called ‘adaption time’ – to

focus images back. Considering that hen driving at120Km/h, in one second you cover more than 30meters, it is immediately clear that the driver’s sightis temporarly and dangerously limited for quite along distance. This is why lighting at the entrance andexit of tunnels must be particularly intense in thedaylight and weak during the night.

For this reason, Tecnositaf engineers leveragedWonderware solutions’ capabilities to create anintelligent management system based both onseasonal timetables and on the brightness detectedby twilight sensors. This smart management systemallows limiting costs and extending the operating lifeof the installed lamps.

The same control system is able to constantlymonitor the status of all switches and lamps, offeringthe operators in the control room real-time visibilityinto all the plants and enabling immediate remote orlocal intervention in case of need.

A Valuable Help in Event of Fire

However important, venting and lightingmanagement does not always require real-timeintervention and can tolerate partial delays. In eventof fire, every second can make the difference forpeople trapped in the tunnel. For this reason Tecnositaf, not least to comply with

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Figure 2: Longitudinal and roof venting system telecontrol.

severe international regulations, invested in thecreation of a particularly robust and effectivesystem. The need to ensure highest quality standardscontributed to the choice of a SCADA systembased on Wonderware System Platform, combinedwith a proprietary system.

The SCADA system itself, in fact, constantlydiagnoses the status of the fire-fighting system,notifying any disfunction and activation.Perfect efficiency and timely activation of the plantrepresent two crucial factors engineers took intoconsideration upon development of the plant.Perfectly working pumps and valves must also beautomatically activated, with no room for error. For this reason, the SCADA system analyzes CO2concentration levels and air opacity, constantly

comparing them with historical data and valuesretrieved in tunnels. This way the plant can easilydistinguish initial fires linked with sudden increasesin values detected by sensors in a limited area, fromthe passage of particularly polluting vehicles, thanksto the integration with videosurveilance systemscarrying out smoke detection functions, too.

In this case, afther the activation of fire-fightingsystems, smoke extractions systems come intooperation according to pre-set schedulations, inorder to facilitate evacuation and rescue proceduresto the rescuers called by the Centralized ControlRoom.

All these solutions allow ensuring the highest safetylevels as today possible, improving safety of driverson the A32 highway.

This document was realized thanks to the support of: Tecnositaf S.p.A.

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Industry: Transportation

Transports Publics de la Région Lausannoise (tl) SAwww.t-l.ch

“The simplicity andflexibility ofWonderware makes ita user-friendlysolution parexcellence”

Laurent Arn,Director, Mauerhofer & Zuber

Wonderware and Mauerhofer & Zuber join forces for the safetyof Lausanne’s M1Tramwayby Wonderware Switzerland

Goals:• Relocate and consolidate traffic management;• Revamp the entire remote control system in order

to improve traffic visibility;• Archive all of the events needed for maintenance

and scenario reconstruction.

Challenges:• Implementing a new system without disturbing

current line operation;• Meeting the safety requirements of the ‘Office

Fédéral des Transports’ (OFT – Swiss FederalTransportation Office);

• Tailoring graphic representations to the customer’swishes.

Wonderware Solution:• ActiveFactory software;• InTouch HMI;• Wonderware System Platform.

Results:• Successful implementation without traffic (very

dense) interruption/disruption;• 7.8 km of M1 line fully monitored with one

ergonomic, advanced application;• Real time and historical access to all types of

information (alarms—safety—traffic).

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Lausanne, Switzerland – The Mauerhofer &Zuber Company Entreprises Electriques SA (MZ) isbased in Renens (VD) and has a subsidiary inMartigny (VS). It conducts most of its business inRomandie, Switzerland, but operates throughout therest of Switzerland and internationally as well.

MZ was established in 1905 and has deep roots inthe region’s economic base. In 2000, it was boughtby the Atel Installations Techniques Corporation,providing it the advantage of the flexibility andresponsiveness of a small business combined withthe stability of a large company. MZ’s primary fieldsof business are: railway safety systems, Road trafficmonitoring, overhead electric lines and low, medium,and high tension cables optical telecom and fibers,electrical grids and electrical engine inspection.MZ can study, build, and maintain systems in all ofthe fields listed above. In addition, MZ designs,develops, and manufactures its own line of productsfor road traffic management and railway safetysystems. The company has 150 employees who havea high-level of training and motivation. More thanone third of its employees work in the researchdepartment. In addition to offering the best servicesat the best price, MZ is committed to quality andsustainability, as proven by its internationallyrecognized ISO 9001 certificate (quality), ISO 14001certificate (environmental management), andOHSAS 18001 certificate (health and safety in theworkplace).

The TSOL - Tramway du Sud-Ouest Lausannois,(Lausanne Southwest Tramway), which was renamedM1 in 2000, began running on June 2, 1991.

It connects the center of Lausanne [Switzerland]with major universities and Renens. The total cost ofoperation (infrastructure, equipment, station, rollingstock) rose to 192M CHF (Swiss francs). TheCanton of Vaud invested 47%, the [Swiss]Confederation 30%, municipalities 11%, the TSOLCorporation invested 7% and TL (TransportsLausannois – Lausanne Public TransportationCompany) invested 5%.

M1 is a light, single-track above-ground system thatserves as the backbone of public transportation insouthwest Lausanne, Switzerland. In addition to 95%exclusive right-of-way, the 1984 preliminary designstudy shows that the line provides service to 33,000inhabitants and 32,000 jobs, not includinguniversities. The route is 7.8 km long and has fifteenstations. It is connected to the rest of the publictransportation network by four connecting stations:Flon, Bourdonnette, the EPFL (Swiss FederalInstitute of Technology) station, and Renens, which isthe only direct connection between the M1 andSwiss Federal Railways (CFF).

The Lausanne Southwest tramway currentlytransports 10 million travelers per year with 17electric railcars and more than 300 trains per day.One train runs in each direction every five minutesduring rush hour.

A Delicate Move

Because of transportation growth and theconstruction of M2, the Lausanne public

transportation company(TL) decided to consolidatetraffic management intoone location at theirheadquarters in Perrelet.

The M1 control desk waslocated at the TSOL stationand therefore had to bemoved. This task wasentrusted to MZ whichspecializes in engineeringand railway safety, anddesigned the current

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Figure 1: The different levels of the remote control system’s architecture.

system. The MZ remote control system was initiatedin 2004 and built between 2006 -2008. It was firstinstalled and tested in Ecublens, then transferred toPerrelet.

The system has two control stations that eachcovers the entire line. Only one person is neededfor monitoring and handling special events orbreakdowns, as well as conducting a series of systemtests, for switches in particular, before the first trainsbegin to run in the morning.

MZ Remote Control System

The MZ remote control system meets the need thatrailways have for a cost-effective remote control andSCADA system based on open-ended, high-performance technology.

Normally, safety systems are operated manuallythrough control boxes or desks. The MZ remotecontrol system replaces these manual systemswithout affecting the level of safety guaranteed bythe interlocking signal boxes. It has only onesoftware program (Wonderware System Platform),regardless of the type and size of the system to beinstalled.The system includes the following components:• Siemens S7 type programmable logic controllersfor the interface with the interlocking signal box;• An Ethernet / TCP-IP communications system.

Industrial, redundant equipment, whichincreases network availability;• Secure servers for hosting the remotecontrol application and a server thatrecords events and alarms;• High-availability monitoring stations withtwo PCs and four screens.

Another advantage of the systemdeveloped by MZ is that it allows to makesubsequent changes to the IT infrastructureby adding hardware, without having tomodify any of the software.

Servers and Their Software

For security reasons, the servers are installed in twodifferent locations in the Perrelet station.

The following software solutions are installed onthese servers:• Wonderware System Platform, a completesoftware solution for automation applications andindustrial information systems. It marks thebeginning of a new era for operating and updatingcurrent industrial applications more effectively andprovides the best methods for designing andimplementing new technical systems;• AlarmDBlogger, a data acquisition software enginethat can retrieve alarms and events generated by thesystem and store them on a history server;• Wonderware Historian, a software program basedon the Microsoft SQL Server which stores all datafrom the infrastructure managed by theWonderware System Platform software.Customized reports can then be created throughMicrosoft SQL Server Reporting Services;• Wonderware Industrial Application Server 3.0. Thissoftware is the remote control source program. Itsapplication is stored in an SQL database andprotected by a password. It can run the operatingmodules for the object-oriented application;• The traffic management centers are installed in thecentral control station. They are equipped with aWindows XP Pro operating system, WonderwareInTouch 10.0 supervisory control software, and theWonderware Industrial Applications Server 3.0software platform.

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Operating Principle

The SCADA system makes it possible to sendcommands through the communications networkand programmable logic controllers to the safetysystem, which will in turn accept or refuse thecommand. The SCADA system shows the status ofthe safety system in real time. This providesrepetition status. The role of servers is as follows:• The primary server hosts the remote controlapplication• The secondary server hosts the same applicationas the first. If the primary server malfunctions, thesecondary server takes control of the system.• The third server hosts the SQL database thatrecords all of the system’s alarms and events.

The function and graphic objects library created byMauerhofer & Zuber is absolutely vital to the

development of future applications. Withthe reference library (switches, signals,safety, etc.), designing a new applicationconsists of logically organizing objects,modifying them, and bringing them intoproduction.

This object-oriented software capability hasenabled Mauerhofer & Zuber to deploy theMetro M1 stations in just a few days, ratherthan the several weeks needed with thesoftware used by MZ in the past.

Remote Control and SystemMonitoring

Remote control and system monitoringensure that the entire system is working

properly. In case of breakdown or failure, theremote control system becomes inoperable and theinterlocking signal box stops responding tocommands from the remote control systems. Inaddition, statuses are invalid and the block diagramsdisplay a system default. System alarms and events are recorded in a 2005SQL database server (Wonderware Historian) withdifferent levels of severity being assigned to theitems. Alarms are acknowledged via a mechanismand cannot be deleted from the database. Users canmanage alarms, look up alarm and event history, andprint reports from the management center.

Moreover, the system includes features for managinguser rights: access rights are managed by user namewhile tasks on the system are recorded with thecomputer’s name.

This document is realized thanks to the support of:Mauerhofer & Zuber SA.

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Figure 2: The M1Tramway at EPFL station.

Industry: Water Treatment

Comunidad de Regantes de Motril-Carchuna y Cota 2000www.icr-sa.com

Motril-Carchuna automates & remotely manages irrigationthanks to Wonderware technologyby Wonderware Spain

Goals:• Promote Agricultural development through an

exhaustive control of irrigation;• Immediately detect irregularities in the system;• Apply more efficient irrigation programming by

centralizing all processes.

Challenges: • It is difficult to supervise a large facility. The

irrigation area of Motril-Carchuna-Cota 2000(Granada) covers an area of 2,535 hectares. Itincludes 3,000 parcels and 2,400 water users.


Results:• Remote control has been achieved in the entire

irrigation distribution network without affecting theoperators;

• The Wonderware solution helps monitor the stateof the network in real time, making the detection ofbreakdowns faster;

• Wonderware’s ease of use makes it possible toeasily change, add or delete any parameters;

• Consumption is optimized in accordance withwater resources and demand.

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“We use Wonderware technology because of itsgreat versatility, robustness and ease-of-use.”

José Rodríguez, President, Irrigation Community, Motril-Carchuna

Motril, Spain - The community of Motril-Carchunahas implemented a complete solution based onWonderware technology that manages its irrigationby remote control. All the control functions areautomated and this provides great reliability andmajor saving in costs.

Making the Most of Natural Resources

As a result of the global climate change during thelast few years, the state of the environment greatlyworries society today.

Spain has a semi-arid surface area and over two-thirds of these are great extensions of irrigated land.However, there is a lack of water resources in Spainand supply is irregular.

Increase in water consumption, inadequatemanagement and prolonged periods of drought haveled to the implementation of control measures tomanage water supply. This was done in order to stoplow water supply from having an even greaterimpact on the agricultural and service sectoreconomies.

Many of the irrigation communities in Granada had‘extremely precarious’ irrigation networks in 2007.This made the government activate projects thatwould modernise the irrigation system incommunities like Motril-Carchuna-Cota 2000. Theirrigation area of Motril-Carchuna-Cota 2000(Granada) covers an area of 2,535 hectares. Itincludes 3,000 parcels and 2,400 water users. Itrecently adopted a wireless consumption networksupplied by Wonderware to control and manage theirrigation system.

The automation and management of irrigationsystems is one of the measures that manycompanies are adopting to enable optimum waterresource management in agriculture. This helps tooptimise the recording and distribution of waterusage. The establishment of pressure irrigationnetworks supervised through centralised remotecontrol systems helps to provide a balance in workconditions. This makes irrigation-on-demandpossible in areas with sufficient water resources.

Complete Remote Management Solution

The irrigation community of Motril-Carchunadecided to implement a HIDROBUS-RF system,which is a complete solution for irrigation. Thesystem involves the design of remote irrigationterminals using Wonderware software.Communications are carried out through anoptimised wireless network (ULP). Low-cost alkalinebatteries power the remote terminals.

The Wonderware System Platform was used withGoogle Earth 3D visualisation. This combinationprovided great precision in the supervision andcontrol of the facility. It also provides a flexible visualenvironment for geographically distributedapplications with high number of nodes.

The HIDROBUS platform is comprised of thefollowing elements: Wonderware System Platform atthe core. It also includes the Wonderware Historian.Clients, with whom the operators interact, receiveupdated and historical information from theWonderware System Platform and WonderwareHistorian. The OPC server (OLE for ProcessControl) helps sending the information to the othercontrol and management programs.

The implementation of this system achieves threemain goals: 1. To promote agricultural development through anirrigation control system;2. To immediately detect possible irregularities in thesystems; 3. To apply more efficient irrigation system bycentralising all the processes.

In the words of José Rodríguez, president of theirrigation community of Motril-Carchuna: “We optedfor Wonderware software because of its great versatility,robustness and ease-of-use.”

Implementation Challenges

Motril-Carchuna is a collective network makingsystem implementation very difficult. To overcomeall obstacles, it was necessary to establish acentralised management system to remotely

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supervise and control the water connection onthousands of parcels based on the needs of users,the availability of water resources and crop type.

Manuel Morales, secretary of the irrigationcommunity of Motril-Carchuna, comments: “It isessential to use solutions like those from Wonderware inmodern and environmentally sustainable systems todaybecause it helps to manage the extensive irrigationnetworks”.

Remotely managed irrigation systems require theestablishment of communication between thecontrol centre and the thousands of nodes in greatlydispersed irrigation points. Each node readsconsumption, pressure, volume and the control ofvalves.

Ingeniería y Control Remoto (ICR) S.A. is thecompany in charge of responding to all thesechallenges. As Technical Director, Lucas Galánexplains: “We already had experience in Wonderwaresoftware. Before beginning implementation, we still hadto conduct tests on new specific parts of the solutionsuch as the integration of Google Earth.”

Main Benefits

The benefits were realized not long after systemimplementation. Remote control has been achieved

in the entire irrigation distribution network withoutaffecting the operators. The Wonderware solution also helps monitoring thestate of the network in real time, making thedetection of breakdowns faster.

Moreover, it is now far easier to make changes tothe solution. Wonderware’s ease of use makes itpossible to easily change, add or delete anyparameters.

Remote control and updates of the software andfirmware of all the elements making up the controlsystem can be made without much difficulty.

José Rodríguez, president of the irrigationcommunity of Motril-Carchuna, confirms this andnotes that: “Added to all these advantages are costsavings in pump operation. We are able to optimizeconsumption in accordance with water resources anddemand.”

There are huge advantages provided byWonderware technology for Ingeniería y ControlRemoto, S.A.

According to Galán, “Wonderware provides greatflexibility and this makes it easier to do changes in thefuture. There is greater integration with other systemsand the driver development tools are easy to use. Thesoftware helps in standardisation as well.”

This document was realized thanks to the support of: José Rodríguez, President of Comunidad de Regantes de Motril-Carchuna,Javier Fernández Lorca, Managing Director, and Lucas Galan, TechnicalDirector, Ingeniería y Control Remoto, S.A.

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Global Water Management, LLCwww.gwresources.com

“…we can addressproblems before theyoccur. It’s the big picturewe need to fine tune andsolve complexproblems.”

James Taylor, Operations Manager, Global Water Management, LLC

Wonderware Software Solution Helps Water Utility MeetQuality, Efficiency and Profitability Goalsby Wonderware

Goals:• Provide ample water and meet county, state and

federal quality standards;• Use less power, conserve energy and operate more

profitably;• Reduce operator time spent driving to remote

locations to save fuel and vehicle costs;• Improve measurement of treatment processes and

gather historical and real-time equipment data forbetter preventative maintenance.

Challenges:• Aggressive timeline required the new system to be

operational within a few weeks;• Operations cover a 100-square-mile territory with

eight separate facilities.

Wonderware Solution: • ActiveFactory software; • InTouch HMI;• SCADAlarm software;• Woderware System Platform.

Results:• The Wonderware software solution’s

standardization and repeatability resulted in quickdevelopment time;

• Historical data and trending reports now areavailable to management for improved decisionmaking;

• Preventative maintenance has extended equipmentlife; power use is minimized and operations aremore profitable;

• Remote visibility saves operator travel time and hasimproved efficiency while reducing fuel and fleetmaintenance costs.

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Phoenix, Arizona – As the fastest-growing privatewater company in Arizona, Global WaterManagement, LLC has a dual purpose: to deliverclean drinking water to residential and commercialcustomers throughout the state, and to providereclaimed water to irrigate parks, schools and golfcourses.

The utility considers both the citizens and theenvironment as its customers. This is especiallyimperative in the desert where it’s possible tosupply enough water for everyone – as long as thisprecious natural resource is carefully conserved.And that’s where Global Water makes its greatestcontribution. The company is known for theprogressive implementation of leading-edge systemsthat enable it to provide ample water as well asmeet county, state and federal water qualitystandards, plus save energy and operate profitably.

The Global Water Wish List

One of the important factors in this reputation forinnovation comes from the company’s continuousevaluation of its operations.

Not long ago, Global Water’s management teamdeveloped a list of desired, additional capabilities.They wanted improved measurement of theirtreatment processes, better ability to recognize andcorrect possible quality problems before theyoccurred, and more comprehensive historical datato assist with management decisions.

They recognized that if they could save power, theycould also save money. Plus, because Global Wateroperates eight facilities in an approximately 100-square mile territory, they envisioned decreasedtime driving between their locations, which wouldsave on vehicle wear and tear, fuel costs andoperator hours spent on the road.

Global Water contacted the local authorizedWonderware distributor, Wonderware West and CPControl Technologies, LLC, an Arizona systemsintegrator. The three entities formed a team thatwould work together to meet Global Water’s list ofneeds.

Rapid Development and Deployment

Not only did Global Water have a clear vision ofwhat they wanted the Wonderware softwaresolution to provide, they also had an aggressivetimeline. Four of the utility’s sites needed to bedeployed at the same time, and CP Control wasasked to complete the project within weeks.

The Wonderware System Platform gave the systema firm foundation, including patterns to follow forstandardization of the system design. I/Oconfiguration from the PLCs, object modeling andgraphics, tags and naming conventions were set fromthe beginning. Then they were also used by thedevelopers and engineers who took responsibilityfor the system post-deployment.

Jeromy Peterson, CP Control Technologies’ ChiefOperating Officer, says, “After the upfront investmentin development, you get great time savings. It hasallowed us to build in more features that Global Waterwanted and still finish on time. From a developer’sstandpoint, it made us look pretty smart!” Hecontinues, “We did triple the work in one-fourth of thetime because Wonderware software’s repeatability anddeployment of objects makes development so easy.”

On the strength of this standardization, the first sitewas completed in about a month, and the additionalthree sites came online within a week.And, as Global Water’s Wonderware softwaresystem has continued to evolve, the solution’s store-and-forward capabilities have provided stability.When adjustments are made, store and forwardsafeguards data and helps prevent losses.

Seeing the Big Picture

Now that the system was in place, it was time to seeif it could help Global Water’s management tobetter process data for planning and performancemeasurement.

In the past, historical data was not gathered at all,and the amount of current information that wascollected provided a mere snapshot of the complexoperations. Engineers used hand-written log sheets

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and entered results into a monthly report. Thismade it difficult for management to identify trendsand make forward-looking decisions.

But Wonderware software changed all that. The newsolution gives Global Water engineers the ability totrack multiple points of input and hundreds of datapoints in real time. Wonderware Historian andInTouch HMI (Human Machine Interface) screengraphics organize this information and make it easilyunderstandable, which has made operators moreefficient and proactive. And the data can be trendedover long periods of time to create better decision-making input for management.

According to James Taylor, Global Water OperationsManager, “The greatest benefit from our system istrending. We can understand what’s going to happen,and we can address problems before they occur. It’s thebig picture we need to fine tune and solve complexproblems.”

The accurate reporting and trending that comesfrom the new Wonderware software enables GlobalWater operators to make use of KPIs, standardizetheir best practices, adhere to EPA standards – anddo it all efficiently. For example, data from theWonderware solution shows when filters will needto be replaced. Backwashing and change-outs can beplanned so that the system’s performance is notdisrupted.

Reports also prove that water remains within EPAcompliance standards for quality. COO Petersonexplains, “Previously, we affected our KPIs with manhours, but now we can affect them with technology.”

‘Powerful’ Cost Savings Now and in theFuture

Power is another central consideration since it’s asignificant operational cost. For Global Water, theWonderware software solution monitors theenergy usage of all pumps, identifying those that maybe malfunctioning.

By performing preventative maintenance morequickly and improving the efficiency of the pumps,equipment life is extended, power use is minimizedand Global Water realizes more cost savings andoperates more profitably.

Taylor says that this is the basis for Global Water’sfuture plans for the Wonderware system. “We’vedecided to implement power quality monitoring withWonderware software in all of our facilities on a fasttrack. We will have it throughout our operations withinthe next year,” he predicts.

This will give Global Water the ability to monitorand track power usage, compare it to water supplyand pump speeds, and track true metrics. Taylor

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continues, “The substantial cost savings go along withthe ability to ensure compliant operations and maximizethe ability to monitor our operations.”

Compliance is the Key

The ability to track trends and monitor operationsis essential for planning and proving compliance, butremaining within strict compliance guidelines at alltimes is also aided by the Wonderware solution.

Wonderware SCADAlarm software capabilityenables Global Water to set alarms for customizedconditions, see visual indications of systemperformance and notify operators of currentconditions, no matter where they may be. This means that the company can enforce stringentEPA mandates for water quality.

Peterson says that, above all else, compliance isGlobal Water’s mission and that WonderwareSCADAlarm software is his most useful tool forensuring it. It enables the utility to affect changesimmediately and maintain constant control, plus thesolution is also easy to use.

The alarm set points can be quickly updatedwhenever standards change, whether they comefrom the EPA, the state or the county.

Remote Visibility Provides Environmental Benefits

With the Wonderware solution, Global Waterenjoys better visibility to its widespread operationsand has made additional operational improvements.Screens in the control room of the main facilityshow all of the equipment, so the need foroperators to drive out to pumps and stations isminimized, saving time as well as fuel, maintenanceand wear on Global Water’s fleet of service vehicles.And these results align with the company’senvironmental goals.

Successfully Fulfilling Multiple Missions

With this deployment, both Global Water and CPControl Technologies have achieved their objectives.As the developer, CP Control Technologies has builta new system that addresses the critical needs ofthe customer, including meeting the deploymentschedule and the operational goals for improvement.And Global Water is benefiting from theWonderware software solution’s capabilities thatfacilitate the utility’s pledge to provide clean, safewater to citizens, to meet environmental andcompliance standards, and to do it all efficiently andprofitably.

This document was realized thanks to the support of: Global Water Management, LLC.

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Ontario Clean Water Agency (OCWA)www.ocwa.com

“The reliability we have with the Wonderware Historian isphenomenal. Because of the store and forward feature, it eliminatesany loss of data. That’s critical to the whole system because we haveto report that information to our regulatory body.”

Robert Simpson, Manager, Asset Management and Operational System Support, OCWA

Ontario Citizens Enjoy Consistent, Clean Water Thanks to a Wonderware Software Solutionby Wonderware

Goals:• Provide consistent high-quality water and

wastewater treatment services; • Build in scalability and standardization to improve

efficiency;• Control costs; do more work with fewer staff in

less time; • Provide the highest levels of regulatory compliance.

Challenges:• Vast service area; wide-ranging customer types and

sizes; • Strict quality/compliance regulations must be met

while delivering cost-effective service; • Provide continuity plus accommodate future

technology integrations.

Wonderware Solution: • ActiveFactory software;• InTouch HMI;• SCADAlarm software;• Wonderware System Platform.

Results:• Scalable; ideal for wide area installations and

communications;• Adding new customers costs less and is

accomplished in hours rather than days;• Increased location support without increase in

staff;• Real-time reports have improved analysis and proof

of compliance;• Changes required for regulatory compliance can be

tested and deployed in one day.

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Toronto, Ontario – Just as water is always inmotion, so is the Ontario Clean Water Agency(OCWA). Since 1993, OCWA has operated in acompetitive market, providing a comprehensivearray of water and wastewater services tomunicipalities, private sector companies and FirstNations throughout the vast province that is twicethe size of Texas. Each day, OCWA produces over700 million liters of drinking water and treats about1.2 billion liters of wastewater at 502 facilities allacross Ontario.

Of course, when it comes to water, delivering aclean, consistent and safe product to all citizens isparamount. After protecting public health and theenvironment, priorities turn to delivering valuethrough outstanding service and cost-effectiveoperations.

OCWA has kept these goals in sight as it has madestrategic moves forward for its customers. In 1999,the agency developed the first Supervisory Controland Data Acquisition (SCADA) system in Ontario.Called Outpost 5, it was designed to work acrosslarge geographic areas providing monitoring,reporting and security. Outpost 5 is still in use atover 750 OCWA locations and is the largest suchsystem in the North American water andwastewater industry.

Riding the Wave of the Future

But OCWA’s commitment to innovation did notstop there. In 2003, the agency recognized anopportunity for progress. What if Outpost 5 couldbe transitioned to a new system that wouldintegrate an off-the-shelf solution with the currentnetwork base? Blending Outpost 5 with such aresource would provide the best of both worlds andcarry OCWA and its customers into the future. Itwould enable the agency to operate more efficientlyby taking advantage of templates and redundancyscenarios to roll out new locations more quicklywith fewer staff.

As envisioned by OCWA, the right solution wouldalso improve their competitive advantage.Customers who choose OCWA as their provider

today would have the option to take control of theirsystem – without re-engineering – if they wished todo so in the future. They would simply purchase thenecessary licenses to continue to run theapplication.

And finally, this new approach would also providegreater continuity of service and quality control tomeet regulatory requirements across the province.

Turning Vision into Action

The research and development and IT departmentsat OCWA converted these ideas into specificationsand sought out possible partners. Through theprocess of evaluations and presentations, it becameclear that Wonderware offered critical advantagesbased on similarities it shares with the Outpost 5model. A transition to a Wonderware softwaresolution would be eased because of scalableconfiguration and template structure as well asstrong web-based capabilities. Plus, WonderwareCanada East, the local Wonderware distributor forthe project, added applicable experience andoutstanding service capabilities.

The Importance of Standardization

For OCWA, economies of scale are imperative.With over a million square kilometers of territoryto cover, the agency’s teams are highly coordinated.Skilled technicians travel to remote locations forinstallations. Then they rely on colleagues working atthe Toronto office to perform the programming, andstill other groups in OCWA hubs around theprovince monitor and maintain the systems.

None of this would be possible without a versatilesolution that enables standardization. OCWA’sInstrumentation, Automation and SCADA Group isresponsible for deploying all of the installations. Thisteam found that the highly flexible WonderwareSystem Platform and InTouch HMI (Human MachineInterface) could be integrated with Outpost 5 aswell as OCWA’s existing asset management systemand Process Data Collection (PDC) database. Plus,with Wonderware software’s template capabilities,

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the system could be replicated consistently andquickly at new installations.

Ciprian Panfilie, SCADA Developer Team Lead,explains, “It’s easy because everything is developed as atemplate. We have a template structure at theWonderware System Platform level, the reporting level,the security level, the graphic level, and we havetemplates that integrate with other packages as well. Wehave them all here in our lab so everything is fully testedand we maintain our standards.”

This brings a major advantage when new stationsare added. Before integrating the Wonderwaresolution, OCWA required a complex,interdisciplinary team to work for six months to ayear on new deployments. Now, they can do thesame work with one person in about three months.And in the case of installations where the hardwareis already in place, projects are even faster; bringingthe system online in large plants has gone frommonths to days.

Calculating Compliance

Along with these deployment advantages, the newsolution also provides extensive measurementcapabilities that are necessary for regulatorycompliance in Ontario. Both OCWA work teamsand emergency response teams rely on the systemfor real-time data about pump pressures, powerconsumption, piping systems, chemical levels andother performance factors. The data is used torespond to immediate needs, but also to compilereports that are required by the Ministry ofEnvironment.

George Terry, Vice President of Operations andMaintenance, says, “It’s not enough just to do anexcellent job in ensuring compliance at all times. Whatyou have to ensure is that you are recording anddocumenting that work.”

It is also critical for OCWA to be able to defend itsreporting. The agency is required to provide regularinformation to the Ministry of Environment. Thisdata, collected from numerous sources such as thepumps that deliver the water, the regulators that

manage the chlorination and the labs that test theeffluent, is reviewed, checked and rolled up intoquarterly reports to prove compliance.

Robert Simpson, Manager, Asset Management andOperational System Support, elaborates, “We have todo this so that people are aware that they have a systemthat’s working properly and providing them with clean,safe drinking water and properly treated wastewater. It’sa continuous process.”

That’s where the Wonderware Historian comes in. Itenables each hub to record data in real time andconverts it into reports that are submitted to theMinistry of Environment. And because of theextensive communications connections built intothe system, staff throughout the operation canaccess the data instantaneously.

In eastern Canada, where severe weather is part ofthe picture, protecting OCWA’s data is another areawhere Wonderware can help. Wonderware Historian forward is a sophisticatedcapability that maintains system data even ifcommunications lines are temporarily down.Performance measurements – some taken asfrequently as every five minutes – are stored locally,if needed, then forwarded to the central databaseonce communications are reestablished. Previously,OCWA had been hampered during power outagesbecause remote staff members were not able toaccess records when connections were interrupted.Now access is optimized and data is protected.

Proactive Maintenance Promotes Quality of Life

As the data is being collected, it is being monitoredby OCWA’s maintenance management system.Programmed with guidelines and allowable rangesfor operations, the system automates the generationof alerts and work orders. Of course this benefitscustomers because it helps OCWA deliver aconsistent product and a high level of service. But italso brings advantages to the agency’s workers. Thework orders enable crews to be proactive, sincethey can highlight budding problems before theyprogress.

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Additionally, management can better utilizepersonnel throughout the province. While thereare hundreds of OCWA locations in Ontario,there are not hundreds of staff. So theWonderware solution’s web-based desktopcapabilities mean that maintenance can beperformed remotely. Simpson puts it this way,“You can be ahead of problems before they happen.Wonderware enables you to respond in a timelymanner using a remote desktop. The last thing you dois physically go there.” So it saves fuel costs, vehiclecosts and operator time.

The wide-area SCADA system also providesbetter work-life balance for OCWA’s maintenancestaff members. Because most corrections aremade remotely, workers don’t have to travel asmuch. And when system adjustments are needed,they usually can be addressed during the normalworking day, eliminating more-expensive, on-callhours. But if alarms do come in overnight, staff canlog on to the internet, make a correction and goback to sleep.

Flowing into the Future

The OCWA system incorporating theWonderware software solution is considered

cutting edge in North American water andwastewater management, but the agency isdriven to implement further innovations.Plans include expanding web-basedcapabilities so that customers and partnerscan log on and see how their systems andservices are operating, includingperformance information and qualitymeasurements. Plus, OCWA envisionsexpanding its work with small- and medium-sized utilities so that all municipalities inOntario have access to the latest technologyfor clean water service.

OCWA is also partnering with First Nationsin Ontario. The agency hopes to be aresource for high-quality water andwastewater services as well as emergencycapabilities.

Simpson sums it up by saying, “The mostimportant benefit is that it provides a scalablesystem for our clients whether they are small orlarge. It incorporates the best technology andsoftware available and gives us the total solutionto meet their needs, and meet all regulatoryrequirements to provide safe, clear drinkingwater throughout the province of Ontario.” Andwith Wonderware, that’s sure to continue.

This document was realized thanks to the support of: Ontario Clean Water Agency.

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Puerto Rico Water and Sewage Authority www.acueductospr.com

“Using Wonderware software has made this plant therole model for the Metro region. It has helped usimprove and maintain the quality of the waterproduced in this facility – which is excellent!”

Nancy Caceres, Plant Manager-Guaynabo, Autoridad de Acueductos y Alcantarillados

Puerto Rico Water and Sewage Authority Delivers IncreasedCustomer Satisfaction with Wonderware Solutionby Wonderware

Goals:• Maintain high quality standards for EPA compliance;• Increase efficiency of management for one of the

world’s largest system platform installations;• Enable better visibility and troubleshooting for over

1,500 sites;• Provide higher capacity output while controlling

costs.

Challenges:• More than 120 different platforms to be integrated;• Needed faster deployment of new installations;• Tough terrain with areas where radio and DSL

communications can’t reach.

Wonderware Solution: • ActiveFactory software;• Wonderware Industrial Computers (InTouch HMI

embedded);• Wonderware System Platform.

Results:• Output has increased from 12 million gallons to 20-

30 million gallons; • Cost savings estimated at $15 million over seven

years;• Fewer shutdowns and improved customer

satisfaction due to proactive trouble shooting; • Island-wide standardization for faster installations

and increased operator ease-of-use;• Clean, EPA-compliant water.

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Puerto Rico – Since being discovered byChristopher Columbus in 1493, Puerto Rico haslived up to its name as a ‘Rich Port’. But since theisland lacks a source of fresh water, inhabitants havealways had to be wise with this precious resource.

During Spanish Colonial times, the military built fivelarge cisterns beneath the Main Plaza to collect rainwater. But today, with a population of almost fourmillion people, the nation’s needs for clean drinkingwater and waste water treatment are much moreextensive. The system that serves them has grownto over 10,000 miles of water mains and aqueductsand 2,000 miles of sewage lines.

This large operation is managed by the Puerto RicoWater and Sewage Authority (Autoridad deAcueductos y Alcantarillado de Puerto Rico). Theagency supervises over 1,500 sites that provideservice to all five regions of the island. More than120 platforms have been deployed, making it one ofthe largest System Platform implementations in theworld today.

Investing in Progress

The Puerto Rico Water andSewage Authority’s strength is notjust in its size. The agency iscommitted to advancedtechnology that enables it toprovide the highest-qualityservices. Wonderware distributoriMiS has been a key partner,working with the Authority to meetits aggressive objectives.

The latest updates were deployed so that theWater and Sewage Authority could increase wateroutput, maintain EPA compliance, improve efficiencyand also control costs. And while these goals maysound contradictory, with iMiS and the Wonderwaresolution, they were all possible.

To do it, iMiS recommended the addition of a state-of-the-art security system, high-speed historical datacollection and components that would enable

centralized management of 100% of the agency’scritical facilities.

Improving Efficiency and Quality

The first step was to transition to a fully automatedsystem. By eliminating as many manual operations aspossible, the Wonderware solution enabled theAuthority to reliably control all aspects of the waterand waste water treatment system – and to beproactive about it. Jose Luis Muñoz, President ofiMiS, explains, “The Water Authority has changed from areactive system to a proactive system with theWonderware solution. We know what’s going on now,rather than having users tell us.”With real-time diagnostics, operators monitor thequality of the water and the treatment processes,plus they can make timely changes that help preventcompliance violations. Also, with the addition ofWonderware Historian, data can be gathered andorganized easily and quickly for the monthly reportsrequired by the Environmental Protection Agency.

This means that the quality of the water ismaintained consistently and the Water

and Sewage Authority is meetingcompliance regulations.

The agency has gained bettertroubleshooting capabilities aswell. According to Muñoz,with system-wide data attheir fingertips, decisionmaking is much more rapid

and efficient. Hector Sanabria,Information Technology

Director, agrees, “You have all of theinformation in front of you. Therefore,

once you see different alarms within thesoftware interface, you can make decisions. You do nothave to go directly to the facilities because you can seethe information on the screen.”

Communications Across the Island

Increased visibility and reduced travel to the manysystem sites is critical. Because the agency serves

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ActiveFactory software, Wonderware Industrial Computers(InTouch HMI embedded), Wonderware System Platform.

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the island’s entire diverse and remote terrain, theWonderware solution also needed to providebetter communications. Various technologiescombine to solve this challenge, including framerelays, radio, DSL and satellite links. Time and moneyare saved because trips to remote sites areminimized.

More Water Without Increased Costs

With a growing population and brisk tourism, thedemand for more water in Puerto Rico is constantlygrowing. This is another area where the newWonderware solution has solved an importantchallenge. Because, even though more water isneeded, the ability to provide it cost effectively isalso a requirement.

The new solution has enabled system-wideconsistency in monitoring and allocating resourcesand overall output has steadily grown. Sanabria says,“We’ve used Wonderware software to analyze ourprocesses and capacity. And based on this data, we’verealized that we can, in fact, increase our output.” TheAuthority now produces 20 to 30 million gallons of

water, up from 12 milliongallons before theWonderware solution wasimplemented.

And the increase has beenaccomplished without taxingthe Authority’s budgets. Theagency estimates that withinabout seven years, the newsystem will save Puerto Ricoclose to 15 million dollars.

Customer Satisfaction isthe Ultimate Goal

With the Wonderwaresolution in place, the Authority

is realizing substantial benefits:• Facilities in all five regions operate consistently andmaintain the same, high quality of water and wastewater treatment;• Standardization, enabled by the WonderwareSystem Platform, allows resources to be allocatedamong the regions as needed;• New stations can be deployed faster, also throughstandardization;• Automatic fault detection of remote PLCs, pumps,sensors and instruments minimizes the need formanual inspections, saving time and money;• Real-time monitoring and alarms improve controlof the operation and prevents sewage overflows andwater distribution faults.

But the most important result of the new solution isthat the customers of the Puerto Rico Water andSewage Authority are experiencing better service.

Thanks to the dedication of the agency’smanagement and staff along with a valueddistributor partner and advanced automationtechnology from Wonderware, the island’s citizensare enjoying abundant, clean water deliveredconsistently and cost effectively.

This document was realized thanks to the support of: Puerto Rico Water and Sewage Authority and iMiS.

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ActiveFactory software, Wonderware Industrial Computers(InTouch HMI embedded), Wonderware System Platform.

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Figure 1: Guaynabo water treatment plant.


Tragsa (Empresa de Transformación Agraria, S.A.)www.tragsa.es

“Each remote control system for irrigationmanagement is a new example of optimizationand improvement. The technology helps makeefficient use of Spanish natural resources”

Félix Díaz de Rada, Director, Department of Irrigation Modernisation, Tragsa.

Balearics Optimises the Water Resources of its Water UsersIrrigation Using remotely Wonderware Technologyby Wonderware Spain

Goals:• To reuse and optimize water resources;• Create a system that is self sustaining;• Simplify integration and make it available to future

irrigation communities.

Challenges:• Include various elements differentiated from each

other: waste-water treatment plant, a intermediatewater storage reservoirs systems, its associatedhydraulic system and remote control system;

• Control the water from crops.


Results:• With the integration of the Wonderware System

Platform, the irrigation communities have a simpletool that stores water user administrative data;

• The solution optimises water consumption anddistributes water fairly based on farmers’ requests;

• The system helps make consumption forecastsbased on demands.

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Balearics, Spain - The Ministry of Environmentand Rural and Maritime Affairs (MARM) committeditself in 2008 to modernise various irrigationsystems on the Balearic Islands in order to create aproductive, sustainable and high quality agriculturesystem.

The main goal of this Project is to reuse wastewater for irrigation by modernising and optimizingvarious irrigation communities.

A Project Aimed at Sustainability

Reusing wastewater is important part ofsustainability. This is especially true in Balearicswhere demand increases considerably in thesummer when droves of tourists arrive at the islandat the same time that the crops need for water is atits greatest. This is why the optimisation of waterresources has become one of the main goals.

The project includes various elements that include awastewater treatment plant, an intermediate waterstorage reservoirs system, its associated hydraulicsystem and a remote control system. The differentirrigation systems have their own local controlcenters with a general control centre located inPalma de Mallorca.

MARM, through Tragsa, is responsible for carryingout this project. It is managed by Adasa, anEngineering company specializing in technologicalsolutions relating to the management of the integralwater cycle and the environment and WonderwareArchestrA-certified system integrator.

Choosing Wonderware

Wonderware System Platform was chosen after athorough evaluation. The solution, based onArchestrA technology, includes WonderwareApplication Server, Wonderware InTouch HMI(Human Machine Interface) and WonderwareHistorian for data control, visualisation and storage,respectively. The complete solution has beeninstalled in the seven local control centres and in thecentral control room. The Wonderware System

Platform provided huge improvements inproductivity and scalability for the distributedautomation applications.

The data acquisition, alarm and event, data handlingand development makes it a great solutions forsimplifying, maintaining and managing any distributedapplication.

The solution provides the necessary flexibility forpossible extensions with new equipment andrequirements. This is possible in the future when theintegration of ultraviolet treatment systems,meteorological stations, desalination plants andother systems needs to be implemented.

“One of the matters that concerned us was the difficultyof individually controlling the quantity of water supply.The remote control system helps to control the waterconsumption from each of the different communities,making it possible to regulate consumption,” Félix Díazde Rada, Director of the Department of IrrigationModernisation, Tragsa.

Efficiency, Effectiveness, Easy Implementationand Use

Ensuring water supply quality for all users andfacilitating decision-making for system managersimproves irrigation system efficiency.

The implemented Wonderware solution places vitalimportance on the four main points that make upthe control system:1. Communication architecture: Grouped intwo blocks:

a. Local control centres: Thanks toWonderware System Platform software, theequipment can be supervised locally;b. Central control centre:• The Wonderware System Platform applicationprovides important information to 10 concurrentusers at the same time (via mobile, PDA, ADSL or3G, for example);• Website application: Helps to monitor andmanage the system’s irrigation terminals. Userscan access information from anywhere in theworld via a computer or mobile device.


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Moreover, they can follow any changes inconsumption and export the displayed data to anexcel spreadsheet for greater comfort and easeof use;

2. Watering control units:The remote unit usedis the aquaReg system, manufactured and supplied byAdasa. It is responsible for closing and opening theelectrovalve and the reading and transmission ofcounter’s pulses;3. Control automation: it manages pumpoperation and communication using the localcontrol centre;4. Control centre:The SCADA system in the localcontrol centre is responsible for supervising and

operating all local equipment.Information from all thepumping and irrigation is alsotransmitted to the controlcenter.

“The remote system not onlyhelps having control over thewater resources, but it also makesoperation very easy for users whoare not accustomed to this typeof technologies”, points outEnrique Santarrufina, Worksand Projects’ Coordinator atBalearics, MARM.

Better Control, Less Costs

“Although it is too early toprovide specific data, it did nottake long for us to evaluate a

return on investment for the project, as the result ofmore efficient water management and connection withthe invoicing systems of the irrigation communities”,affirms Gloria Cabot Batlle, Project Manager, Adasa.

The benefits of the irrigation automation are quicklyseen once the system was implemented.

With the integration of the Wonderware system,the irrigation communities have a simple tool thatstores water user administrative data. It optimises water consumption and distributeswater fairly based on farmers’ requests. It also helpsmake consumption forecasts based on demands.

This document was realized thanks to the support of:Félix Díaz de Rada, Director of the Department of Irrigation Modernisation,Tragsa, Enrique Santarrufina, Works and Projects’ Coordinator, Balearics,MARM, and Glòria Cabot, Project Manager, Adasa, ArchestrA-certifiedsystem integrator.


Figure 1: Irrigation SCADA System.

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NOTES

161

NOTES

EUROPE

Austria, HungaryWonderware GmbHwww.wonderware.at

BelarusWonderware Belaruswww.wonderware.by

BeNeLux (Belgium, Netherlands,Luxembourg)Wonderware Beneluxwww.wonderware-benelux.com

Czech & Slovak RepublicsPantek (CS) s.r.o.www.pantek.cz

DenmarkWonderware Scandinavia ABwww.wonderware.dk

EstoniaWonderware Estoniawww.wonderware.ee

FinlandWonderware Finlandwww.wonderware.fi

FranceWonderware Francewww.wonderware.fr

GermanyWonderware GmbH www.wonderware.de

GreeceControl System Ltd. www.controlsystem.gr

IcelandTölvusalan HFEmail: [email protected]

IrelandWonderware Irelandwww.wonderware.ie

Italy Wonderware Italia S.p.A. www.wonderware.it

LatviaWonderware Latviawww.wonderware.lv

Lithuania Wonderware Lithuaniawww.wonderware.lt

NorwayWonderware Scandinavia ABwww.wonderware.no

PolandAstor Sp. z o.o. www.astor.com.pl

Russia & CIS Wonderware Russiawww.wonderware.ru

Portugal SA, Soluções em Automação, S.A. www.sa.online.pt

Serbia & Montenegro ACE – Automatic ControlEngineeringwww.ace.co.yu

Slovenia, CroatiaWW Engineeringwww.wweng.com

Spain Wonderware Spainwww.wonderware.es

SwedenWonderware Scandinavia ABwww.wonderware.se

SwitzerlandWonderware Switzerland SAwww.wonderware.ch

Turkey EST (Enerji Sistem TeknolojileriSanayi) www.estenerji.com

UkraineWonderware Ukrainewww.wonderware.ua

United KingdomWonderware United Kingdomwww.wonderware.co.uk

AFRICA

South AfricaWonderware Southern Africa www.wonderware.co.za

ASIA & SOUTH PACIFIC

AustraliaWonderware Australiawww.wonderware.com.au

ChinaWonderware Chinawww.wonderware.com.cn

Wonderware Guangzhouwww.guangzhouwonderware.com.cn

Beijing BlueBird AutomatizationTechnology Co., Ltd.www.bluebirdme.com

Qingdao Gaoxiao InformationIndustry Co.,Ltd.E-mail: [email protected]

Chongqing Runfeng Science &Technology Co., Ltd.www.cqrfkj.com

Shanghai BlueBird M&E Co., Ltd.www.bluebirdme.com

Shanghai EastDream AutomationControl Tech Co, Ltd.www.eastdream.net

Utitech Technology (Beijing) Co.Ltd.www.utitech.com.tw

Xi’an king-mount Automation Co.Ltd. www.king-mount.com.cn

Yunnan Summit Technology Co.Ltd. www.summittech.com.cn

Zhuhai Telead Mechanical &Electronic Co. Ltd. www.telead.gd.cn

Hong KongTecoford Ltd.www.guangzhouwonderware.com.cn

IndiaWonderware IndiaEmail: [email protected]

KLG Systel Ltd.www.klgsystel.com

162

WONDERWARE REPRESENTATIVES

IndonesiaPT Trimaxindo Adimitrawww.trimaxindo.com/wonderware

JapanWonderware Japanwww.wonderware.jp

Canon IT Solutions, Inc.www.canon-its.co.jp

Nittetsu Elex Co. Ltd. www.ns-elex.co.jp/index.htm

Korea, SouthWonderware Korea Ltd.www.wonderware.co.kr

INO Technologies Inc.www.ino.co.kr

Maha Net Co. Ltd.www.maha-net.co.kr

Sammi Information System Co.Ltd.www.sammicomputer.co.kr

MacaoTecoford, Ltd.Email: [email protected]

MalaysiaIAM-Wonderware Sdn Bhdwww.iamgroup.com.my

New ZealandProcess Software Ltd.Email: [email protected]

Pakistan Agatos Pakistan (Pvt.) Ltdwww.agatos.com.pk

Philippines Precision Motion Control Phils.Inc.Email: [email protected]

SingaporeWonderware of Singapore PteLtd.www.wonderware.com.sg

Servo Dynamics Pte Ltd.www.servo.com.sg

TaiwanUtitech Technology Co. Ltd.www.utitech.com.tw

ThailandSagitate (Thailand) Co. Ltd.www.sagitate.com

Viêt NamQ Systems Ltd.www.qsystemsco.com

MIDDLE EAST

Israel Instrumetrics Engineering Ltd. www.instrumetrics.com

United Arab EmiratesPrecast FZCOwww.wonderwareme.com

U.S. & CANADA

Akamai Controlswww.akamaicontrols.com

Alaska Instrument Co.wwwalaskainsrument.com

Wonderware Centralwww.wonderwarecentral.com

Wonderware Cincinnatiwww.atrdist.com

Wonderware Great Plainswww.wonderwaregp.com

Wonderware Midwestwww.wonderwaremidwest.com

Wonderware NorCalwww.norcal.wonderware.com

Wonderware NorthEast www.wonderwareNE.com

Wonderware PacWest www.pacwest.wonderware.com

Wonderware Southeast www.wonderwarese.com

Wonderware West www.west.wonderware.com

Wonderware Canada Eastwww.wonderwarecaneast.ca

LATIN AMERICA & THE CARIBBEAN

ArgentinaWonderware Argentinahttp://latino.wonderware.com

BrasilWonderware do BrasilEmail: [email protected]

ChileARTARON S.A.www.artaron.cl

ColombiaColsein Automatizacion yNeumaticawww.colsein.com.co

Costa RicaGNE Automatización Industrial deCentroamérica S.A.Email: [email protected]

México Wonderware de Méxicohttp://latino.wonderware.com

Puerto RicoiMiS (Integrated ManufacturingInformation Systems)www.imispr.com

Venezuela Wonderware Venezuelahttp://latino.wonderware.com

WONDERWARE REPRESENTATIVES

Invensys Operations Management5601 Granite Parkway Suite 1000Plano, TX 75024 U.S.A.Tel 1-469-365-6400www.invensys.com

©2009 Invensys Systems, Inc. All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing from Invensys Systems, Inc. Invensys, Wonderware, InTouch,ActiveFactory, InBatch, SCADA, SCADAlarm and ArchestrA are trademarks of Invensys plc, its subsidiaries and affiliate companies. Microsoft, Windows, Vista, Visual Studio, BizTalk, SharePoint,Microsoft Office and Internet Explorer are registered trademarks of Microsoft Corporation. All other brands and product names are the trademarks or service marks of their respective owners.