Agenda. 1. Check Weighing 2. Business Needs 3. Solution & Case Study

Transcription

1 process weighing Hardy delivers productivity solutions to manufacturers and processors Hardy developed the first PLC integrated weighing system We are a Rockwell Automation Global Encompass Partner We were founded as Hardy Scales in 1918 Hardy is part of Roper Industries, a $2B+ public company

2 How to Develop Static/Dynamic Check Weighing Solutions using off-the-shelf components from Rockwell Automation and Hardy Process Solutions. Overcome the Black Box, Green Board Problem! Learn how manufacturers and OEMs in the food and consumer packaged goods industries are improving product inspection capability using off-the-shelf components to deliver amazing results. Components include: PLCs and Human Machine Interface from Rockwell Automation and high-speed check weighing bundles (instrument/sensor) from Hardy.

3 Agenda 1. Check Weighing 2. Business Needs 3. Solution & Case Study

4 Agenda 1. Check Weighing 2. Business Needs 3. Solution & Case Study

5 1. Many applications. Static and Dynamic. Verify package contents Check product tolerance Classify product Identify parts Overload safety check SLICING BY CHECK WEIGHING SORTING BY CHECK WEIGHING CATEGORIZATION BY CHECKWEIGHING PUSH-UP CHECKWEIGHING PUSH-OVER CHECK WEIGHING TARE & GROSS WEIGHT FILLING MULTI TRACK CHECK WEIGHING

6 1. Many stand-alone check weighing solutions.

7 1. Many production requirements. 7

8 Agenda 1. Check Weighing 2. Business Needs 3. Solution & Case Study

9 2. The Problem Expensive Green Board Custom Hardware Software that is proprietary and/or obsolete Maintenance that can be unreliable.

10 2. What do manufacturers want? Off-The-Shelf technology. Also called Open Source Must meet specifications Must be reliable Above all the must be easy to integrate, use, modify and fix.

11 Agenda 1. Check Weighing 2. Business Needs 3. Solution & Case Study

12 3. Hardy & Check Weighing

13 3. Why are we different. Open-Architecture Platforms Non-black box solutions Direct RA Connectivity 3 levels of solutions Configured, Flexible, Packaged Service-Lite Technologies Hardy s ToolBox makes it easier

14 An off-the-shelf solution HI 4050CW

15 3. Hardy s Solution Product Overview Easy to Install, Use, Maintain & Change Lower. Cost Effective. It s not a black box, it is an off-the-shelf solution. It integrates to Rockwell and other PLC s. Up to 250 packs per minute It breaks the traditional analog strain gauge speed barrier, without the cost of MFR (Magnetic Force Restoration or Other similar high speed/resolution technologies) Smart Features It offers advanced EDGE DETECTION (weight on & weight off) and operator indication of DATA QUALITY

16 3. Hardy s Solution Bundle Specifications (Controller)

17 3. Hardy s Solution Bundle Specifications (Loadcell) Load Cell Capacities: 2, 5, 10 kg up to 100kg Load Cell Accuracy: Better than % of capacity

18 3. Hardy s Solution Working out the Solution

19 300g DYNAMIC ROLL TEST 2kg load cell Vertical Axis in grams Horizontal Axis 1 grad = 4 msecs Variation Threshold 3g Motion Threshold 0.5g THE LEDGE Data Capture Starts High Threshold 280g Low Threshold 40g Settling time msec

20 3. Hardy s Solution Case Study The case study outlines the NEEDS, OPERATIONAL & FINANCIAL BENEFITS that Hardy s 4050CW check weighing bundle delivered to a global Consumer Packaged Good manufacturer in the Snack Food industrial market segment. Customer Needs Meet speed spec (<400 msec/weigh) Meets resolution spec (<0.25g/weigh) Reduce product giveaway Uses know, open source technology Easy to use, modify & fix Retrofit into existing system

21 3. Hardy s Solution example MULTI TRACK CHECK WEIGHING #1 #2 #3 EXISTING LINE LANE DIVERTER CHECK WEIGHERS LANE REJECTOR & CONSOLIDATOR EXISTING LINE

22 3. Hardy s Solution Value Delivered a) Reliability and lower life cycle costs. Accelerated ROI. b) Reduction in Finished Product Give Away. Accelerated ROI.

23 3. Hardy s Solution Meeting the Operation Outcomes ROI - WHAT WAS THE OPERATIONAL VALUE? a) Reliability and lower life cycle costs. Accelerated ROI. Off the shelf components that are readily available and supported ongoing. Familiar components/technology that are well known. Component cost is considerably less than the current hardware components. Less dependence on vendor resources for upgrades, modifications, and troubleshooting. Components are robust and not subject to failure due to handling. Limited set of cost effective spares can be kept on-site Easier swap out of hardware Easier upload of software, configuration and calibration parameters dramatically reduces MTTR (mean time to repair) in the event of a failure. Inter component communication via industry standard fieldbus protocols such as EthernetIP One HMI can display the production data for multiple rows The open platform allows for unlimited data collection and transfer to our MES system. Future loop control for weight control, and other controls enhancements are easily added. Depending on application: ROI can be reduced from years to months or months to weeks.

24 3. Hardy s Solution Case Study ROI - WHAT WAS THE DOLLAR VALUE? b) Reduction in Finished Product Give Away. Accelerated ROI. Estimated savings per portion Estimated savings = ~0.36% of finished product = ~1$ Million in savings per month