Our client is one of Malaysia’s most established latex disposable glove manufacturers. They export to up to 90 countries around the world with a compounding capacity exceeding 10,000 metric tonnes per annum.
Projects
Recipe Management System for Chemical Compound Batch System
Background
Challenge
Their compounding system uses manually operated equipment, with spreadsheets to record batch parameters and recipes. All the information was stored in Excel sheets and hardcopy, making these data not easily accessible across all levels of operations. The quality of products was not consistent and was prone to human-error. They required allocation of labor to operate machines and record data.
Solution
Recipe management system with automated batching system to achieve the following:
- Automated batch process without manual intervention
- Centralized recipe management system to manage all recipes
- Reduction in production cost by 10%
- Accurate and reliable data collection and reporting
Result
Our solution brought about a transformation in the way batch production is carried out. It reduces the intensity of manpower required to operate the system, while ensuring product quality is enhanced. It eases the visibility of the batch quality through detailed reports that allow easy identification of production abnormalities.
Validation System for Cylinder Filling Station
Background
Our client serves as a leading industrial gases and engineering company, serving a variety of end markets such as chemical and energy, manufacturing, food and beverages, electronics, healthcare, and more.
Challenge
Conventionally, the operators select the type of gas and size from the HMI of the filling station, then the system will automatically fill the cylinders with the specified recipe selected. However, they experience the risk of placing the wrong cylinder with the selected recipe. This results in risk of explosion and filling of incorrect content to the cylinder.
Solution
Validation system that pulls and compares data from their inventory management system to achieve the following:
- Barcode system to scan cylinder and retrieve information via REST API from their inventory management system
- Calculation and comparison made to ensure the selected recipe matches with the specification of the cylinder
- Interlock system to prevent the filling process if cylinder validation has failed
Result
Our solution places an extra layer of safety standard that mitigates the risk of incorrect filling of cylinders. The system integrates data availability from their existing system with shop floor operational data to achieve a more secure operation process.
Central Monitoring System for Heating Jacket System
Background
Our customer supplies heating jackets designed for gas process and exhaust piping systems. These heating jackets prevent the build-up of contaminants and reduce system maintenance time.
Challenge
Their PID temperature controllers are connected to a localized operator interface. Operators are required to go to the production floor to check each unit for temperature and alarms. Maintenance checks and works are manually recorded on paper, resulting in a tedious maintenance work flow. Historian values of each temperature controller are stored locally making general analysis a chore.
Solution
Centralized monitoring system that collects information across all controllers providing the following benefits:
- User-friendly web application to browse and filter data for quick analysis
- Immediate notification of alarms or abnormalities in the system
- Maintenance history recording
- Consolidated data storage and data history
Result
Conax Automation successfully delivered a software platform for centralized monitoring of distributed localized data. Maintenance records are properly documented, easing the workload to perform manual routine checks on each temperature controller.
Digital Reporting for Consumer Manufacturing Process
Background
Our client was founded in Japan and began operation in 1891. They are a global manufacturer and sale of customer hygiene-related products such as toothpaste, soaps, detergents, skin-care products, and many more.
Challenge
Their batching process requires operators to manually record batch mixing data onto hardcopy checklist sheets. Subsequently, the operator then keys in these data into an Excel spreadsheet to calculate the raw material consumption by day, month and year. Data recorded on the spreadsheet often times were inaccurate and were prone to mistakes, resulting in inaccurate analysis of batch quality.
Solution
Digital reporting system that communicates directly with shop floor equipment providing the following features:
- Gateway to collect batching data from client’s SCADA system via OPC UA
- Store in SQL database the batch details for each step consisting of the set point parameters and actual dose value
- Batch reports and raw material consumption reports automatically generated and stored on the server
Result
We have centralized our client’s data from various plants into a dedicated server, enhancing data accuracy and enabling near real-time visualization. This consolidation fosters transparency and improves quality on the production floor. Consequently, the client has been able to reallocate manpower to tasks of higher value.
Plant Information Management Cloud System for Cocoa Manufacturing Process
Background
Our client is one of the major cocoa ingredient producers in the world. They have a global presence in more than 65 countries, with a total of 180,000 metric tonnes of total cocoa bean processing capability across their facilities.
Challenge
Their manufacturing process consists of a DCS system to control and monitor the production floor. Data within the DCS system was isolated, and not used to add higher value operational insight to their business. The client intends to implement SAP ERP system however, there was a gap between passing data from DCS to their ERP system.
Solution
PIMS Cloud for Data Collection and Vertical Integration, providing the following benefits:
- Gateway to collect and store data from their shop floor controllers
- OEE dashboard to provide insight to production efficiency
- Digitalize their production floor alarms and provide actionable insights from the alarm data
- Vertically integrate shop floor data into their SAP HANA hosted in Google Cloud
Result
Our solution has significantly optimized our client’s operations through vertical integration from the shop floor to the ERP level. By automating data transfers into the SAP system, we have eliminated the necessity for manual data entry by the workforce. Furthermore, our system actively analyzes alarm data, leading to a 10% reduction in unplanned production downtime.
Waste Tracking System for Hazardous Waste Management
Background
Our client is a leading American solar technology company and global provider of responsibly produced eco-efficient solar modules advancing the fight against climate change. Their solar technology embodies sustainability and responsibility towards people and the planet.
Challenge
The solar panel manufacturing process relies on many well-known toxic chemicals. These chemicals must be properly handled to mitigate the risk of exposure by the public and the environment. Their current practice involves a routine check on the production floor by the storage team to ensure that all the waste is periodically transported and stored. Likewise, the storage team has to manually monitor the levels in their waste storage tanks and notify the disposal team when the containers are full and ready for disposal. This resulted in a labor-intensive waste management system with no proper method of tracking that all waste is properly handled.
Solution
Waste Tracking System Interdepartmental Implementation achieve the following benefit:
- Ticket order system to facilitate communication across departments
- Waste level tracking system to identify total waste collected in containers
- Barcode system for effective record and tracking of waste containers and pellets
- Digitalized reports for waste inventory overview and planning
Result
Our Waste Tracking System (WTS) has established a standardized operating procedure for their waste management, ensuring that all waste is effectively and accurately tracked and documented. This has significantly streamlined their compliance with auditing requirements. Moreover, the detailed reports generated by our system offer valuable insights, enabling their management to optimize operations and minimize waste generation across various processes.
