Production data acquisition in the fields of bottling and packaging provides real-time information from the process and thus the basis for the optimization of operational sequences and product quality assurance.

Tasks of PDA

• Acquisition of consumption values and quantities produced
• Product quality assurance
• Weak point analysis and preventive maintenance
• Determination of the performance of machines and plants

A production data acquisition system collects the relevant information from the process, makes it available for data visualization and prepares the information for evaluation and analysis.  In this context, it performs the following tasks:

• Online acquisition of machine, process and production data from the controllers of individual production units
• Offline acquisition through manual inputs
• Data visualization
• Fault cause determination and weak point analysis
• Machine-oriented reporting

Acquisition of machine, process and production data

In order to be able to make the relevant information available, data must be recorded for the following categories:

• Equipment, machine, plant section and plant statuses
• Operational and fault messages
• Metered values
• Measured values
• Operating cycles / operating times / maintenance information

Data visualization

To provide a quick overview of the current plant status, the data acquired is visualized in a plant diagram.

The operational statuses of individual machines and production units can be viewed at a glance. Additional PDA data points (e.g. counter readings or measured values) can also be integrated in the representation.

Measured-value acquisition

The measured values acquired by the individual machines can be represented in curves. The free composition of different views is an important instrument in the detection of fault causes.

Data evaluation and analysis

The PDA system provides different analysis options for the evaluation of data acquired:

Fault cause determination and weak point analysis

Fault cause determination is based on a specific weak point analysis of a line's machines and production units. Machines susceptible to faults are identified and optimization potential is detected.  

Plant characteristics

For the evaluation of data based on plant characteristics including efficiency, output and availability, a line's machines and production units are assessed in order to determine their technical performance. The evaluation can be performed for the entire plant, individual machines or plant sections. Data can be represented as trend curves or graphical overviews of the individual production units.

Reporting

Based on different report types, the production data acquisition system provides decision makers in different company areas with relevant information made available as:

• Filling reports
• Shift reports
• Empties reports
• Inspector logs

Package units

In complex plants, it is possible that individual plant sections are provided with autonomous control systems. These independent solutions represent a very specific challenge with respect to their integration into a consistent automation concept. The goal must be to realize a consistent, plant-wide operating philosophy, data acquisition, data archiving and data evaluation solution.

With the Plant Direct iT PU interface, process data is acquired directly via the process control system, visualized in parallel via the PLS and the local control panel, and the operator control can be switched over from the PLS to the local control panel and vice versa.