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安裝羅克韋爾自動(dòng)化PlantPAx 過程控制解決方案，其中包括：
　　? 通過共享的現(xiàn)有光纖網(wǎng)絡(luò)連接到服務(wù)器的Allen-Bradley ControlLogix PAC
　　? FactoryTalk View、FactoryTalk Batch和 FactoryTalk Historian
　　? Allen-Bradley PowerFlex? 變頻器
　　? E3 智能過載繼電器和控制機(jī)構(gòu)
　　? 通過現(xiàn)場總線連接到ControlLogix PAC 的Endress+Hauser 儀表
　　? 戰(zhàn)略維護(hù)合同、團(tuán)隊(duì)支持合同以及 FactoryTalk Asset Centre
取得的成果
　　? 基于S88 標(biāo)準(zhǔn)的整套過程解決方案
　　? 縮短產(chǎn)品上市時(shí)間
　　? 提高產(chǎn)能
　　背景
　　業(yè)界的個(gè)人洗滌用品公司PZ Cussons 投資新建了一家高速洗滌液生產(chǎn)廠，大幅提高了公司產(chǎn)能并從更加的生產(chǎn)過程中獲益。這家公司的舊廠區(qū)曾在過去很長一段時(shí)間內(nèi)發(fā)展得生機(jī)勃勃，但其產(chǎn)量卻達(dá)不到規(guī)模經(jīng)濟(jì)的要求，難以滿足業(yè)務(wù)需求。過去，這個(gè)廠區(qū)幾乎在所有生產(chǎn)階段都出現(xiàn)過操作員過多干預(yù)的問題，這經(jīng)常會造成不希望出現(xiàn)的產(chǎn)品差異。
　　該公司了解到生產(chǎn)操作中其實(shí)可以節(jié)省大量成本，并且意識到只有現(xiàn)代化的過程工廠才能實(shí)現(xiàn)這一目標(biāo)。
　　面臨的挑戰(zhàn)
　　作為改進(jìn)其英供應(yīng)鏈并實(shí)現(xiàn)現(xiàn)代化的一部分，PZ Cussons 決定利用現(xiàn)代化過程自動(dòng)化基礎(chǔ)架構(gòu)提供的控制和可視化功能。在明確建造一家新的英生產(chǎn)工廠的可行性時(shí)，公司意識到舊廠區(qū)的大量現(xiàn)有過程設(shè)備很難滿足現(xiàn)代化生產(chǎn)環(huán)境的需求。
　　這是該公司選擇羅克韋爾自動(dòng)化及其戰(zhàn)略聯(lián)盟合作伙伴Endress+Hauser 所提供的業(yè)內(nèi)的產(chǎn)品和服務(wù)的原因之一。解決方案完全符合ISA S-88 標(biāo)準(zhǔn)且利用聯(lián)網(wǎng)儀表和路由閥，此外，羅克韋爾自動(dòng)化集成架構(gòu)意味著通用的軟件環(huán)境和可擴(kuò)展性，可極大地簡化安裝和跨生產(chǎn)線升級的過程。
　從“全新設(shè)計(jì)”開始，PZ Cussons 認(rèn)識到許多方面都能夠節(jié)省成本并不必要的成本。為了在庫存和交付方面進(jìn)一步節(jié)省成本，公司還希望采用更精益的生產(chǎn)流程。
　　該公司面臨的主要挑戰(zhàn)是如何使過程中的所有步驟都可見并使所有參數(shù)都保持在運(yùn)行允許范圍之內(nèi)。應(yīng)對這一挑戰(zhàn)需要采用極其的批處理系統(tǒng)、混合系統(tǒng)和計(jì)量系統(tǒng)，并要求這些系統(tǒng)之間不僅能夠彼此通信，還能夠與辦公室中的主控制系統(tǒng)通信，而且能通過安全的外部網(wǎng)與外部供應(yīng)商進(jìn)行通信。
　　解決方案
　　利用由羅克韋爾自動(dòng)化設(shè)計(jì)和不斷改進(jìn)的設(shè)備，以及由Endress+Hauser 設(shè)計(jì)和調(diào)試的儀表和現(xiàn)場總線網(wǎng)絡(luò)來開發(fā)和控制全新的加工和生產(chǎn)操作。
　　項(xiàng)目的實(shí)施過程充分利用現(xiàn)場總線設(shè)備所提供的靈活性、改進(jìn)的生產(chǎn)以及診斷數(shù)據(jù)。這為PZ Cussons 實(shí)現(xiàn)了程度的過程可見性，并且能夠控制的設(shè)備遠(yuǎn)遠(yuǎn)不止舊廠區(qū)中所配的設(shè)備。這種新方案幫助公司實(shí)現(xiàn)了預(yù)期的成本節(jié)省，而且還了許多會增加不必要成本的過程變量。


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