With Scada the line runs like clockwork

To make sure that it all runs like clockwork, the Scada system combines everything into one uniform structure. This means that all the machine’s components are integrated, e.g., in the thermoformer, the printer for the lid foils, the camera for product inspection or the barcode reader for the foil barcodes. However, Scada’s biggest advantages and possibilities come from the creation of a line network – i.e. the individual machine networks are combined into one single such network. Centralised line control functionalities can hereby be centralised. This includes higher-level monitoring of the production processes, central user management, operation and data archiving of all machines and components – even third-party ones. Scada shows what it can do: all data is saved on a high-performance server. This is Scada’s central processing unit. Production-driven data, like formats, audit trail data or users, is managed here and production data is acquired (PDA). Data exchange and reconciliation take place seamlessly and continuously across all levels. Data like LOT numbers, barcodes, format parameters, etc. as well as other administrative information is entered centrally via a master line PC, which is also integrated into the line network. The operator can control and administer everything from here.

The machine stops, for instance, if the product inspection reports a preset number of unfilled blisters at short intervals. The cause is localised quickly and can be corrected. Just like in this example, Scada records all deviations during production. These deviations are not only reported by the system but are also analyzed, e.g. with regard to their frequency. The average duration of a machine stop due to an error and the average duration of the correction period are likewise determined. The evaluation takes place graphically in diagrams and can be implemented for each individual machine as well as for the entire line.

Scada automatically monitors, displays and archives critical process values, such as the sealing temperature or the individual machine speeds. Thus, the accuracy of the process factors can also be proven over the years.

Thanks to Scada, the packaging process can be planned across lines. The customer can therefore use the Uhlmann Scada system to create and manage a shift planning model in order to identify production-free periods in advance. Order and article management are similarly carried out over the entire line. This ensures productivity through shorter changeover times because, for example, all variable format parameters like barcodes, camera formats, imprinting and control data, etc. are entered centrally and can be sent to the connected units. Centralised order starting moreover ensures higher efficiency, as the individual machine formats that fit the line format are determined and loaded immediately.

All relevant meter information from the machines is automatically sent to the Scada system, such as produced blisters, cartons, etc. Thus, the productivity of the line and the individual machines can be controlled and evaluated automatically. Owing to the integration of the units into the Uhlmann Scada system, the 21 CFR Part 11 standard for the machine concerned is automatically fulfilled and no further investment is

required. Scada enables process based evaluation and visualisation of all data over the Internet – the data can then be retrieved in an internal network or worldwide at various locations over a web server.

Scada allows easy connection to existing cross-production and higher-level systems such as MES or PPS via open, standardised interfaces like OPC. Secure integration of third-party machines and components takes place in the same manner. Uhlmann – as system provider and integrator – can de-velop and implement any needed drivers

and other programs. Standardised modules and interfaces are used. Individual, lasting and future-proof solutions can thus be realised.

Scada demonstrated its efficiency on a high-speed reference line, consisting of a tablet press made by Fette, a B 1880 thermoformer with a FlexTab high-speed feeder, a tablet lift made by Thomas Büchele Maschinenbau, a C 2404 cartoner, a checkweigher made by OCS and a S 3040 stretch bander. The B 1880, with a capacity of 1300 blisters per minute, set the pace for all components, including the third-party ones, without loss of productivity or quality. Various control components from VisioTec were also integrated into the line: two VisioChrom HR cameras, a high-resolution VisioRead HR camera, a VisioPrint printer and two VisioScan systems. There is no question that, with this level of complexity, a higher-level system control not only does good work but is also decisive for production, because it controls the overall system like a brain. Scada coordinates all machines and components, and networks them into one efficiently operating system. With its intelligent and centralised concept, the system opens up a new level of control for packaging lines as well as data acquisition and evaluation. The software is very flexible and can be customised for individual customer needs. Integration into an existing IT infrastructure is also possible via standardised interfaces. The first systems are already in use.

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