INDUSTRY 4.0 | FACTORY MANAGEMENT A roadmap to Industry 4.0
German PVC compounder Polymer Chemie recently embarked on an Industry 4.0 digitalisation programme with
Poly.ERP software developer Kirchhoff Datensysteme Software (KDS). The two companies share their roadmap here
The central objective of Industry 4.0 is integration of production with existing business applications. The foundation for this integration is harmonisation of the IT landscape and the creation of a unified data basis across the various automation layers (ERP, MES, SCADA, etc). In many compounding companies, however, a wide range of predominantly non-system- based processes prevail. PVC compounder
Polymer Chemie has been a long-time user of Kirchhoff Datensysteme Software’s
Poly.ERP for its resource planning. Next to the core ERP functions, it also has specific end-to-end processes in production planning and control (PPS), quality assurance, recipe management and plant calibration reproduced in the system. Mobile data terminals, tablets and integrated scales have replaced paper-based production processes and, as a result, cumbersome data consolidation and the implementation of interfaces across various levels of the automation infrastructure is no longer required. With this foundation in
place, Polymer Chemie has now committed with KDS to a roadmap of Industry 4.0 initiatives together with Poly. ERP. The first course of action is the system integration of plant controls, which will be achieved through a cost- effective four-step pragmatic
www.compoundingworld.com
The foundation for Industry 4.0 digital competence – an integrated ERP/MES System Source: Kirchhoff Datensysteme Software
and manageable approach that allows for measurable outcomes and is outlined here: n Process data import (not real time): Many Polymer Chemie plant controls are delivering process data in the form of intermittent data exports. Integration of this data will allow for comparison of ‘as-is’ against ‘to-be’ values. The result will be full traceability of production data. n Process data integration (real time): Polymer Chemie will address use cases that yield additional value through real-time data integration. Controls that are able to collect and send real-time data will be linked with the Poly.MIS (Management Information System) analysis tool and transferred data consolidated to the
appropriate functional level. This will enable creation of alarms to prevent defective or costly operation failures. n Connection of dedicated plant controls: Some extrusion equipment includes systems and sensors with their own controls outside of the central control system. In some cases, these allow communication with the central control system, in others they operate stand- alone or lack sensors for data capture altogether. The likely scenario of the digitalisation initiative will be a sensor connected to a decentral control unit. Collected data will be read using a bridge, which acts as an interpreter in the network between the plant controls and other systems (such as MES orERP). The result will be an enriched
data source for analysis and deeper process insight. n In-system-handover of plant parameters in Poly. ERP: The fourth stage of the initiative will see specifications such as plant parameters or recipe mixtures being communicated seamlessly between the Manufacturing Execution System (
Poly.MES) and the plant control system on the other hand. The result will be less error- prone manual processes. According to KDS, what is
important in this four step approach to Industry 4.0 is that the digital initiatives are not implemented as ends in themselves but always on a business case. It says the first steps of the initiative will amortise within the first few months of implementation. �
www.kds-kg.de �
www.polymer-chemie.de
August 2020 | COMPOUNDING WORLD 55
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