Client : SABMiller
Duration : 12 Months
Budget : R2,000,000
In May 2003 SABMiller embarked on a project to replace there existing manufacturing systems software at the Prospecton brewery. This was to be undertaken in multiple phases starting in the brew house through cellars and filtration. The existing system uses Modicon PLCs with Monitrol as the SCADA. The total project was given the name as Project Lightyear.
The new software implementation entails rewriting all the PLC code, replacing the Monitrol SCADA with InTouch, implementing the Archestra framework and developing a batching system so that the process is recipe driven. The entire replacement system was to be based on the S88 modeling standards and all reporting was to be accomplished using INSQL and Active factory.
The Wonderware Archestra system was chosen to be the operator interface as the infrastructure would allow SAB to cope with diverse systems while Archestra's flexibility, scalability and the ability to structure and to reuses engineering effort was required at the time to ensure the project deadline being met. RS Batch was selected to be the batch engine and the implementation was done modular to ensure the production / maintenance personnel having the ability to make changes to recipes and plant operation without having to rely on the System Integrator. All the PLC engineering was completed using Modicon Concept with TSX Quantum Controllers.
CSS were awarded Phase one of the project which incorporated the Raw Material handling, CIP plant, and Brewhouse 2. Following this phase two commenced and included Brewhouse 1, 3 and 4. The Brewhouse upgrade included two batch engines, redundant Archestra application servers and working across 6 Quantum 534 14A CPU's.
With regards to the benefits obtained by the new system, it allowed for a central point of configuration which facilitated ease of change propagation. Through the implementation of standards and the reusability of developed objects, software coding time was reduced and the accuracy improved. This resulted in time saving during FAT and commissioning.
"As to the implementation, we went through the usual learning curve but things went exceptionally well largely because of the backup we received and the expertise of our system integrator, CSS (Convenient Software Solutions)"
Shannon Castle - Manufacturing Systems Manager at Prospecton
