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三家制品企業(yè)成功釋放潛能，實(shí)現(xiàn)持續(xù)優(yōu)化與改進(jìn)
　　制品行業(yè)的生產(chǎn)具有動(dòng)態(tài)性，并且受商品驅(qū)動(dòng)。為了滿足市場(chǎng)的高需求，企業(yè)在考慮采用何種過程、技術(shù)及新技能的時(shí)候，需要打破傳統(tǒng)思想。
　　每一家公司所面臨的機(jī)遇和挑戰(zhàn)都不盡相同。有些公司可能在某個(gè)流程遇到了瓶頸，可以通過加強(qiáng)機(jī)器控制來(lái)加以解決，而有些公司則可能需要提高維護(hù)工作的可預(yù)測(cè)性并減少停機(jī)時(shí)間。盡管問題存在種可能，但解決這些問題的切入點(diǎn)只有一個(gè)，就是實(shí)現(xiàn)互聯(lián)。
　　互聯(lián)企業(yè)的先進(jìn)解決方案和智能機(jī)器可以幫助制造商實(shí)現(xiàn)設(shè)備互聯(lián)并掌握運(yùn)營(yíng)狀況，從而實(shí)現(xiàn)自動(dòng)化和實(shí)時(shí)控制。
　　改善運(yùn)營(yíng)
　　為滿足市場(chǎng)的高需求，Milk Specialties Global 在制造智能方面投入資金，以期能夠?qū)崟r(shí)地分析與掌握運(yùn)營(yíng)狀況，促進(jìn)生產(chǎn)流程的改進(jìn)。
　　該公司在其位于美的三大生鮮奶加工廠部署了羅克韋爾自動(dòng)化的 FactoryTalk? VantagePoint? 企業(yè)制造智能 (EMI) 軟件。在運(yùn)營(yíng)過程中，EMI 軟件可以收集、關(guān)聯(lián)和顯示實(shí)時(shí)的過程、業(yè)務(wù)和實(shí)驗(yàn)室數(shù)據(jù)。它還建立起一套“記錄系統(tǒng)”，用于產(chǎn)生一組一致的事實(shí)信息，以便據(jù)此做出決策。在此基礎(chǔ)上，公司做出了許多合理的運(yùn)營(yíng)調(diào)整和投資，為滿足市場(chǎng)需求起到了關(guān)鍵的作用。該系統(tǒng)顯示，在做出這些積極調(diào)整后，工廠產(chǎn)量得到了明顯提升(增加了 7%)。
　　此外，制造智能系統(tǒng)帶來(lái)的全新分析功能也為工廠控制用水量起到了幫助作用。工人可以隨時(shí)控排水量和水位峰值，密切關(guān)注用水量并解決泄漏等問題，以實(shí)現(xiàn)節(jié)水目標(biāo)。
　　持續(xù)改進(jìn)
　　Agropur Cooperative 發(fā)現(xiàn)，其加拿大 Don Mills 工廠無(wú)法再產(chǎn)生必要的無(wú)縫數(shù)據(jù)，來(lái)持續(xù)改善運(yùn)營(yíng)。為解決這一問題，該公司從羅克韋爾自動(dòng)化引入一套先進(jìn)的解決方案，對(duì)該工廠進(jìn)行了現(xiàn)代化升級(jí)。這一解決方案包含一套 Allen-Bradley? ControlLogix? 控制器、PowerFlex? 變頻器和 PanelView? 人機(jī)界面 (HMI) 硬件。每個(gè) HMI 均基于虛擬化服務(wù)器運(yùn)行FactoryTalk? View Site Edition 軟件，為所有其軟件確定了標(biāo)準(zhǔn)化的環(huán)境。這為大量數(shù)據(jù)轉(zhuǎn)化為有價(jià)值信息奠定了基礎(chǔ)。
　　該公司還安裝了 FactoryTalk AssetCentre 軟件，用以進(jìn)行自動(dòng)化資產(chǎn)管理和版本控制，確保始終使用版本的文檔。FactoryTalk VantagePoint EMI 則進(jìn)一步提升了企業(yè)對(duì)離散系統(tǒng)全部數(shù)據(jù)的訪問能力，使得負(fù)責(zé)持續(xù)改進(jìn)的員工能夠及時(shí)掌握車間狀況。
　　這套集成式控制和信息解決方案可以為工廠經(jīng)營(yíng)者提供必要數(shù)據(jù)，有助企業(yè)做出明智的決策。借助于現(xiàn)代化的系統(tǒng)，該工廠現(xiàn)在每年可節(jié)省 2,500 小時(shí)的手動(dòng)數(shù)據(jù)收集時(shí)間。
　　流程改進(jìn)
　　為實(shí)現(xiàn)流程優(yōu)化，Miraka 攜手羅克韋爾自動(dòng)化部署了一套系統(tǒng)，旨在幫助其新西蘭奶粉生產(chǎn)廠優(yōu)化運(yùn)營(yíng)。該公司在其工廠部署了 Pilion8? 模型預(yù)測(cè)控制 (MPC) 軟件平臺(tái)，這套平臺(tái)包括用于控制、分析、測(cè)、可視化和集成信息及流程的各種模塊，旨在發(fā)現(xiàn)流程改進(jìn)的空間并實(shí)現(xiàn)產(chǎn)能化。
　　在這款創(chuàng)新解決方案的幫助下，該公司的旺季產(chǎn)能提升 4% 以上，濕度目標(biāo)指數(shù)提高 0.04%，同時(shí)還加強(qiáng)了對(duì)蛋白質(zhì)和脂肪的控制，每年減少脂肪和蛋白質(zhì)損失逾 100 噸。此外，機(jī)器的優(yōu)化使得工廠在旺季的每噸奶粉生產(chǎn)能耗降低 1%。
　　通過引入先進(jìn)的技術(shù)和機(jī)器來(lái)收集更多邊緣數(shù)據(jù)，企業(yè)可以深入了解如何充分發(fā)揮智能機(jī)器的潛能，并對(duì)故障做出預(yù)測(cè)，防患于未然。智能工廠經(jīng)過優(yōu)化的互聯(lián)流程可以幫助智能制造商提升產(chǎn)品質(zhì)量，提高敏捷性、增加收入，從而獲得競(jìng)爭(zhēng)優(yōu)勢(shì)。


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