DeltaV process control system provides advanced control such as MPC. Source: Emerson Process.
Two winning projects with im--pressive, measurable results were detailed by Steve Cook, operations manager of Givaudan Flavors (Lakeland, FL), and John Wisniewski, MES global program leader of Wrigley (Chicago, IL). Cook’s project involved the automation of manual batch processes in making extracts from fruits, which increased output and improved asset utilization. Wisniewski’s implementation of a manufacturing execution system (MES) reduced shifts and improved OEE.
Steve Cook outlined the results of automating the company’s Lakeland, FL flavors facility, which was completed in 2004, with additional improvements in 2005. Cook implemented an Emerson Process DeltaV automation system with a Foundation fieldbus network, and installed intelligent flowmeters, put in automated feed-and-recycle valves and traded in the clipboard for a model predictive control (MPC) system. He reported an ROI greater than 25% with a target payback in 2.5 years, but the actual payback was 1.5 years. Cook has been able to identify process bottlenecks and improve OEE, which averaged about 85% in 2007. He saw overall capacity gains of 30% and was able to identify bottlenecks previously unnoticed.
According to Wisniewski, Wrigley decided an MES would be a way to improve manufacturing excellence, especially with Wrigley’s new products. The MES would connect manual data collection systems and HMIs with SAP ERP systems. Wrigley’s MES strategy focuses on lean principles and total productive manufacturing processes. Chosen by Wrigley’s worldwide factory team, a Wonderware MES, based on Invensys’ ArchestrA technology, was tested at a pilot site in Europe and achieved impressive results. A factory cross-functional team (engineering, IT and facility management) worked on the project, whose production line demonstrated a 20-plus point OEE improvement and a continuous improvement in 2007 of five points. The MES has been employed in North American plants and around the world, and has identified opportunities for manufacturing improvements at all Wrigley’s key facilities.
