planemos GmbH implements standardised control system solutions at Privatmolkerei Bechtel (Bechtel Private Dairy)
The history of Privatmolkerei Bechtel (Bechtel Private Dairy) dates back to 1880 (first mentioned in a document in 1908). This century-old tradition involves obligations: The company therefore not only attaches great value to the quality of its dairy products, but also strives to meet the customers’ requirements and legal provisions reliably and transparently. This strategy pays off: Bechtel is in a growth trend and has therefore, amongst other things, repeatedly expanded the factory, which was newly built in 1983 in Schwarzenfeld. Every day, Bechtel processes more than one-and-a-half million kilograms of milk from around 1,700 milk producers here. However, Bechtel increasingly faces challenges regarding care and maintenance, due to the great system diversity in the control and automation technology. Therefore, the company decided to modernise the production on-site with an integrated and standardised control system solution.
Focus on efficiency and quality
The modernisation project adapts to the overall corporate strategy: In 2013, Privatmolkerei Bechtel (Bechtel Private Dairy) introduced a TPM (Total Productive Management) model. The aim of this Bechtel optimisation programme (BOP) is quality-maintaining “zero-defect” production. At the same time, Bechtel has focused its production to the Schwarzenfeld site in recent years and optimised it – partly on the basis of an advanced ERP solution (CSB system), René Guhl, managing partner of Privatmolkerei Bechtel (Bechtel Private Dairy) explains. “All management decisions, operative or strategic, are based on actual live data.”
Martin Miller, Division Manager Quality and Process Management in Schwarzenfeld adds: “We do not want duplicate master data storage and also no interfaces, because this way we can exploit the resources more efficiently, maintain more flexibility and work much more efficient in the end.”
Standardised control system for existing facilities
As a part of this modernisation, Bechtel wanted to implement a control system solution,
by means of which all productions can be operated uniformly, efficiently and safely. Furthermore, the system should also be flexible and simple, to allow integration of future extensions. Bechtel chose Siemens Solution Partner planemos GmbH as the project partner. The automation specialist for recipe-controlled food processes has implemented many control system solutions for dairies, which ensure maximum plant transparency, stable, reproducible processes, working in compliance with the strict hygiene requirements for dairy products.
After extensive comparisons and evaluations of possible solutions, planemos decided to implement an integrated SCADA solution, based on SIMATIC WinCC V7, with the SIMATIC WinCC/IndustrialDataBridge option for Bechtel. This way, production data can be exchanged seamlessly with both, the existing MES systems (Manufacturing Execution System), and the SIMATIC Process Historian for long-term archiving of process data and the SIMATIC Information Server for reporting. This data is stored for up to five years and allows complete production traceability, enabling Bechtel to further improve its quality management. The information can be made available to all terminal devices by SIMATIC WinCC/WebUX, even on mobile terminal devices. This way, Bechtel has full access to all production information at all times.
More transparency, more availability
In the meanwhile, production 1 already runs on the new system, production 3 is currently being put into operation. Advantages of the integrated and standardised solution are already apparent in the everyday operations: The standardised interfaces make operation in production much simpler and more intuitive than before, enabling Bechtel to increase the production and reduce downtimes. Fast and mobile access to management data supports the persons in charge to take a decision and enable the company to react to new requirements in a swift, targeted and flexible way. Also Thomas Bux, Managing Director of planemos, is very satisfied with the project: “With SIMATIC WinCC as the basis, we have implemented an integrated solution, which ensures simple networking of all relevant information: from process and plant data to information on batches, consumption data, stock levels and maintenance measures in the MES, until finally the merchandise management system. Thereby, we significantly contribute to more quality and efficiency for our customer.”
Standardises plant control and visualisation at Privatmolkerei Bechtel (BECHTEL PRIVATE DAIRY)
- production optimisation by standardised control system
- transparent data exchange from the control level via the MES system to the ERP system
- fast localisation of production errors
- location-independent retrieval of management information enables fast, targeted reaction to production occurrences
- higher productivity and product quality
- simple expandability of the homogeneous control system environment when production facilities are expanded
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