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Unlimited History & Expandable SCADA

Tamaki Gives Total Control with Plant Replay System

This case study is adapted from an entry submitted to the ICC 2015 Discover Gallery

Problem

Sinton’s Dairy had several localized SCADA/HMIs that could not connect or share information with different parts of the plant. Operators were constantly having to jump from system to system in order to monitor and control the piece of the plant that they were operating. This brought about problems with tracking down and solving process issues because none of the historical data in these systems could be shared or used outside of the localized HMI. In order to improve usability and expedite problem solving, Sinton expressed the need for a centralized SCADA/HMI system.

Solution

Tamaki Control recommended that Sinton should install Ignition as a centralized SCADA. It exceeded the requirements necessary to provide a centralized control system, and left enough room for future expansion of the system. Using Ignition’s unlimited history, Tamaki was able to store tag history for all tags displayed on screens, operator actions, and alarm logs. With the development of Tamaki’s ‘Plant Replay’, users were able to replay plant screens at a later time, enabling them to see what had happened days, weeks or even months ago. This made it easy for anyone in the plant to effectively troubleshoot and track down production issues.

Result

Sinton’s Dairy has used Ignition and ‘Plant Replay’ to quickly track down and solve numerous process issues since. They now have an expandable SCADA solution that will grow with the plant. They have started the process of moving other areas of their plant onto Ignition, and are planning future expansion projects that will utilize the existing Ignition SCADA.

Sinton Dairy’s CIP, or Clean in Place, system keeps machinery cleaned while handling milk, orange juice, and other dairy products.
A Plant Replay system allows Sinton Dairy to see what happened days, weeks, or months ago.
An overview of the entire plant floor.