MANAGEMENT | INDUSTRY 4.0
Right: Coperion’s CPCC “smart” control system is designed specifically for compounding plant
conditions that can impact quality, Cronje claimed. “Each process step can have hundreds of variables that affect the quality of the output and operational effectiveness. Even the skilled experts lose control of their process.”
His solution is to use AI to find complex patterns
in datasets and develop distinct operating models for the production facility. He points to DataProph- et’s Omni product, intended to reduce the cost of non-quality for manufacturing industries, which can then produce control plans that bring production into a stable and optimised state. “Cutting-edge machine learning techniques allow Omni to understand the effect that a small change in an arbitrary process step will have on all down- stream process steps,” he said. “Process steps are no longer operated and controlled in isolation and for each prescribed change, Omni can quantify the expected magnitude of its effect on production.” Omni is a cross-industry product, but there are
numerous systems, not necessarily with such grand goals, available specifically for plastics compounders.
From line to ERP Coperion says that its Coperion Production Control Center (CPCC) “smart” control system provides compounders with an intelligent solution for the control of compounding systems. “The CPCC incorporates all the essential functions of a manu- facturing execution system (MES), such as company data capture, KPI determination, traceability and order management,” the company says. Critically, CPCC facilitates overall control of continuous production on multiple production lines. Other key advantages cited by the supplier
include complete documentation of the production process and the ability to trace the finished product right down to the batches of raw material used. Its use of generally accepted standards makes it easy to integrate into an existing IT infrastructure. “The CPCC consolidates the experience that
Coperion has gained while implementing over 150 compounding lines and is tailored precisely to compounders’ requirements,” the company claims. “This development enables Coperion to offer its customers an intelligent Industry 4.0/digitalisation application that paves the way to smart factories.” The first CPCC system went into operation at an undisclosed customer at the end of last year, it says.
Transparent production The CPCC automates the key tasks of the produc- tion process by connecting to an ERP system. This then sends the CPCC master formulations contain- ing component proportions and batch data for the raw material used. The system uses this data and previously recorded production line parameters to create “production recipe versions” for that produc- tion line. These include operating and work instructions for compounding line operators. It then performs an automated consistency check. The ERP system’s order planning can then use
the production recipe versions to create an up-to- date list of the production orders that are to be carried out. It then sends this to the CPCC, which passes the production order data to the relevant compounding line and initiates production there. The CPCC records process data for each filled
Above: This pyramid schematic shows how the Coperion CPCC integrates MES, SCADA, and process control functions
30 COMPOUNDING WORLD | May 2019
package produced and sends it to the ERP system. Barcodes make each filled package seamlessly traceable. The ERP system also receives additional information, such as the status of the current production order, and, when a production order is completed, an overview of the raw materials
www.compoundingworld.com
PHOTO: COPERION
PHOTO: COPERION
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