Case Study

Site-Wide Ignition SCADA, MES, and Automation Software for Enhanced Operational Efficiency at Weylchem:

Problem faced:

Weylchem US Inc. faced operational inefficiencies and limited data visibility across its various plant operations. The existing control and monitoring systems lacked the scalability and functionality needed for comprehensive data collection, real-time tracking, and process control across the site. This hindered Weylchem's ability to monitor performance metrics, optimize batch processes, and integrate advanced automation, impacting overall efficiency.

AFI Systems solution:

AFI Systems proposed a comprehensive site-wide Ignition SCADA and MES upgrade. This solution aimed to enhance data tracking, streamline batch processing, and improve operational control. The proposed system included new hardware installations, upgraded PCs, monitors, a control room server, and Ignition software for SCADA and MES functionality.

The project scope included:

Infrastructure Overhaul: Installation of new PCs, monitors, and a server with Ignition software.
Control Room Enhancements: Development of a centralized control room screen with drill-down functionality for detailed monitoring.
Ignition Modules: Implementation of Ignition Perspective and Vision modules for remote access and batch tracking, Ignition Alarm Module for notifications, Historian for data trending, and Reporting for improved data insights.
MES Capabilities: Deployment of Sepasoft Batch and Barcoding modules for efficient batch record management.

Results:

The Ignition SCADA and MES solution provided Weylchem with robust, scalable infrastructure capable of supporting site-wide automation and data management. The centralized control room screen improved operator oversight, while local and remote monitoring enabled continuous access to operational data. These enhancements allowed Weylchem to analyze, troubleshoot, and optimize processes, resulting in substantial gains in productivity and efficiency.

AFI Systems’ tailored solution established a foundation for future scalability, ensuring Weylchem's capacity to expand and adapt their automation strategy as operations grow. This project underscored AFI Systems’ expertise in delivering innovative, effective solutions for complex industrial challenges, promoting Weylchem’s goal of a modernized, efficient facility

Engineering services - standard AFI practices

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