SYSTEM INTEGRATION FOR THE INDUSTRY 4.0
Manufacturing, control, and management
System Integration is an industrial discipline which aims to interconnect the different chain links in the manufacturing, control, and management chain to create a unified system that is simple to use and is cost-effective in the manufacturing phase.
The pyramid diagram shows the different levels that integrate said chain, according to the ISA 95 standard.
On the ground level, or Level 1 of the ISA 95 standard, we find the sensors, machines, and equipment that integrate the manufacturing process per se. Every element that provides some sort of information is connected to a PLC (Programmable Logic Controller) or a Distributed Control System.
There can be a single, general-use PLC, or several PLCs which form an intelligent network used to control different processes. For the sake of simplicity, however, let’s say that there’s a single PLC.
By itself, the PLC is unable to make decisions and monitor process logistics. The process logistics are generally delegated to the different hierarchical levels of the company, depending on the complexity of the decision.
To ensure that technicians can execute those decisions, we provide systems either with one or several HMIs (Human-Machine Interfaces), which come in the form of industrial touch screens with a robust and reliable design, or in the form of PCs, in which we install the necessary software.
The most commonly known and used software is SCADA (Supervisory Control and Data Acquisition).
SCADA displays each and every electro-mechanical instrument of the factory on one or several synoptic diagrams, allowing its status to be displayed and its operation to be changed within pre-established limits. In addition, SCADA shows graphs of the process variables, stores their status in historical records, displays alarm messages, and allows the introduction of operating parameters, permitted logic, etc.
Sometimes it is necessary to record the data of process variables in digital support. In some industries, this record must comply with the legal requirements of non-alteration and encryption, so that it can be downloaded and handed over to the authorities or companies working with the administration for auditing and control purposes. We carry out this process in our products in accordance with the CFR standard (Title 21, Part 11).
The MES (Manufacturing Execution System) is a software which helps production managers establish work orders, priorities, and obtain statistical data which can be used to make better decisions in real time, in line with the production priorities.
The MES uses an automated production management system which can reduce bottlenecks and manual stops used to change materials and tools, as well as the losses incurred in such stops. The MES helps you effectively manage the transformation of materials into finished and packaged products.
The MES could be seen as an intermediate step between an ERP (Enterprise Resource Planning) system, and a SCADA (Supervisory Control and Data Acquisition) system.
PLC
The PLC is the first link in the field element processing chain. It must be programmed so that it can execute all monitoring and production operations without interruption, have an operator-friendly interface, and allow for modifications on the go.
Touch screens
Touch screens can control the plant and other machines, display multiple interconnected systems, have a web server, register data, serve as a gateway, have a VPN router…
Their current technology goes further beyond the simple display of synoptic diagrams and process variables.
SCADA
SCADA (Supervisory Control and Data Acquisition) is a computer software that can control and supervise industrial processes. It provides real-time feedback with the field elements.
Prior to 1990, SCADA was commonly conceived as the plant control and production management software. However, nowadays (Industry 4.0) such concepts are further apart. SCADA now takes over the process supervision and handling, whereas the MES manages the production orders, the data analysis, the decision-making process and in summary, improves the process of transforming raw materials into finished products.
MES
The MES (Manufacturing Execution System) is a software which helps production managers establish work orders, priorities, and obtain statistical data which can be used to make better decisions in real time, in line with the production priorities.
The MES uses an automated production management system which can reduce bottlenecks and manual stops used to change materials and tools, as well as the losses incurred in such stops. The MES helps you effectively manage the transformation of materials into finished and packaged products.
The MES could be seen as an intermediate step between an ERP (Enterprise Resource Planning) system, and a SCADA (Supervisory Control and Data Acquisition) system.