Client Challenge
A major tobacco manufacturer sought to modernize and centralize the control systems for their blending and cutting processes. The facility’s existing setup relied on multiple standalone HMIs and SCADA PCs, including PanelView, PanelView Plus, and Siemens Panels. This fragmented system posed challenges in process oversight, troubleshooting, and operator efficiency.
Our client required a centralized control room to integrate these disparate systems into a unified platform while minimizing production downtime during the transition. The new control room needed to enhance visibility, control, and mobility for operators while incorporating advanced hardware and software solutions to ensure reliability and scalability.
Our Solution
Our team delivered a state-of-the-art centralized control room solution over 14 months, working closely with production teams to manage changeovers and ensure minimal downtime. The $800,000 project involved the following key components:
- System Integration: Existing standalone HMIs and SCADA PCs were integrated into server-based Wonderware or FactoryTalk View SE Distributed Applications. This consolidation provided a unified platform for monitoring and controlling the blending and cutting processes.
- Centralized Control Room Design: The new control room featured:
- 8 x 48” Flat Panel Monitors for process overview and control visualization.
- 4 x 27” Touch Screen Monitors for user interface and interaction with critical systems.
- 6 iPads for mobile viewing and troubleshooting, enabling operators to address issues remotely.
- Redundant Server Infrastructure: A Stratus Server with built-in hardware redundancy was deployed, supporting:
- Virtual servers for FactoryTalk View SE, ThinManager, and SQL Server applications.
- Virtual machines for standalone Wonderware applications.
- This architecture ensured robust performance and minimized the risk of system failures.
- Coordination and Project Management: DSI maintained close communication with multiple teams and customer departments to schedule swap-overs during low-impact periods, significantly reducing downtime.
The Results
The blending and cutting control room upgrade provided the tobacco manufacturer with significant improvements in system performance, reliability, and operator efficiency:
- Unified Process Oversight: The integration of multiple standalone systems into a centralized platform enabled comprehensive process visibility and streamlined control.
- Enhanced Operator Efficiency: The control room’s design, including large monitors and mobile devices, improved operator accessibility and responsiveness.
- Reduced Downtime Risks: The Stratus Server’s hardware redundancy and robust architecture ensured proper system functionality.
- Improved Troubleshooting: Mobile access via iPads allowed operators to identify and address issues quickly, minimizing the impact on production.
- Seamless Transition: Through careful coordination, DSI successfully implemented the upgrade with minimal production disruption.
This project demonstrated DSI Innovations’ ability to deliver complex control system upgrades that balance technical innovation with practical, production-friendly implementation.
