A problem, facing a large beverage manufacturer, was the installed network operating at the plant, connecting the equipment on the production line. The approach that had been adopted was a hodgepodge that had grown with the plant. This resulted in the existence of multiple lines on a single network, an arrangement that worked for a while but clearly was not the best practice going forward. For instance, an obvious limitation was the availability of IP addresses and outages to several lines due to unrelated machine issues on the shared network. New sub-networks were created to accommodate additional lines, but the problem remained in that the original network still serviced multiple different lines.
Process and Data Automation (PDA) was hired to reorganize the existing network and to isolate this equipment from other networks. This required PDA to work with the Client’s IT team to define the new architecture, installers to provide new media (creating a new physical network), and other OEMs to provide the client the correct hardware and programming to meet the client’s new corporate standards.
PDA engineers initially undertook a pre-planning phase, a type of network architecture overview. The preplanning phase involved choosing and assigning IP addresses for each of the machine centers based on the new machine orientation. PDA engineers worked with the key stakeholders (Client, contractors, and OEMs) to provide a roadmap leading from the singular, overlapping network to independent networks for the new, independent lines. That the company intended to simultaneously move an entire network proved to be advantageous since it allowed the rearrangement of things.
The selection of IP addresses followed a pattern that was logical to the actual flow of the line, i.e., machines at the beginning of the line would go to the top of the IP address range. Much of this work utilized an Excel spreadsheet and was done with the technical knowledge of what the IP addresses represented and how they were to be used. PDA engineers went on site to use the new IP addresses that had been selected. This involved accessing the machine centers to reconfigure them to use the new IP addresses. This did require updating not only hardware addresses in network equipment-line network switches, PLCs, HMIs, and gateways. Machine logic for communications also needed to be updated as messages between machinery followed new paths. As needed to assist the Client in meeting its new standards hardware was replaced. This resulted in the need to commission the new switches on this new network.
A significant challenge to the work arose from the fact that the company was completing physical changes to the line while PDA was disentangling the IP addresses. For example, the equipment from one line was disassociated with its former line and reused on the second while needing to minimize downtime. This interfered with the ability of PDA to focus on just one line, and it became necessary to consider both lines since changes were occurring simultaneously. A further challenge arose with the changing of some switches, for which the available documentation did not match the actual reality. It was found that for some older switches it was necessary to reset them before changes could be made. PDA corrected the documentation where it was necessary, i.e., when it did not match reality, and labeled the equipment to simplify further work on the network.
PDA engineers successfully untangled the lines and networks, taking it all back to its’ roots and rebuilding to give better isolation between the systems. The changes made by PDA have represented a significant improvement, providing reliability, and eliminating any dependency of one line upon another. The operation of the machines has also improved. From the standpoint of administration and management, the changes realized an improvement due to the clear separation of the lines. Future upgrades would be to improve operator visibility, possibly deploying a comprehensive level package SCADA or MES.
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