Project description
1. Planner
Currently the production manager of a plant organizes / plans productions, taking into account 2 or 3 aspects this means that we have a lot of downtime.
Normally, our customers' production lines are not independent and there is a strong relationship between them. In other words, to produce a product they need about 40 raw materials and each can go through about 5 lines previously. This makes planning very important in order to reduce downtime and increase production.
We want to create a planner that does its planning work based on sales orders or production needs, but also takes into account different process variables (production capacity, storage capacity, production speed, resource states, pollution reduction, reduction change of formats, maximum efficiency, cash flow ...)
It is about creating a process planner that also takes into account the characteristics and needs of the production units.
2. Sequencer
Once we have a work order in process, in some cases we have to take a product from a deposit to a computer or vice versa. This operation is done by activating or deactivating motors and valves, the problem is that there are many combinations. It is about making a sequencer that tells the PLC what elements it has to start and in what order.
3. Golden batch
There are many sources of variation in a batch process from variations of raw materials (humidity, proteins, fat...), different batch durations, changing environmental conditions, fluctuating utilities... Simply automating the batch process by replicating every aspect of the Golden batch recipe won't always give us new batches with a performance similar to that of the Golden batch. This is because other key sources of variation, such as changes in raw material quality, are not addressed.
The objective is that, based on all this information, create the Golden batch of each line or process, which should allow us to adapt the process and its behavior taking into account behavior models of latent variables. The system, following the progress of each new batch, makes small corrections to the standard operation at some critical decision points, in order to maximize performance and ensure quality.
4. Virtual assistant
The goal is to implement one more layer in the HMI/MES interface that is to move from helping and training operators for their operations. This assistant must allow any operator with minimal training to operate the plant without any problem. The idea is that it helps simplify the creation of work order, stock regularization....
