Project Name: Manufacturing Process Control and Information Management System (MPCIS)
Client: PT. British American Tobacco (BAT) Indonesia
Implementation: December 2003 - August 2004

Description

MPCIS is an integrated information system of PT BAT Indonesia for managing tobacco data in area of PMD (Primary Processing), SMD (Secondary Processing) as well as Quality area. MPCIS handles Automatic Data Capture from PMD and SMD machines as well as Manual Data Entry, supports the integration of other company’s application and databases and enhances the Corporate Performance by providing fast and accurate information. MPCIS provides real-time data and trending from both PMD and SMD; analysis tool such as Statistical Process Control (SPC); integration with quality / laboratory data such as Freeway and VIDES; integrated reporting system of PMD, SMD and as well as Quality

Implementation Benefits

-  Reduce company operational cost by eliminating unnecessary existing application

-  Provide accurate maintenance management system to support company Total Predictive Maintenance Program

-  Provide timely information and reports, helping key decision makers make informed decisions

-  Improve product quality by providing real-time data and implemented Statistical Process Control

-  Providing a continuous, comprehensive, processes and overall production performance

Scope of Supply

A. MATERIAL SUPPLIES

1. Interfacing System

1.1 Server PCs
1.2 Converter for Field Instrument to Ethernet protocol
1.3 I/O Servers
1.4 Network Communication (UTP cable, NIC, Switching Hub, etc)
1.5 Wonderware InSQL Starter Bundle Software License

- Industrial SQL Server 100 Tags
- Active Factory Per Server (Concurrent) 2 User
- FSCAL2000 2 User

2. Other Hardware’s

2.1 UPS (Uninterrupted Power Supply), for one hour capacity

3. Consumable and Spare Parts

B. ENGINEERING & INSTALLATION SERVICES

1. Interfacing System

1.1 PLC/Controller Program Review

• S5 CPU 943
• S5 CPU 928B
• S7 300-2DP

1.2 PLCs configuration

• S5 CPU 943 - 3 point
• S5 CPU 928B - 3 point
• S7 300-2DP - 1 point

1.3 Device’s module adapter installation and configuration

• S5 CPU 943 - 3 point
• S5 CPU 928B - 3 point
• S7 300-2DP - 1 point

1.4 Cable installation : 19 point
1.5 Switch installation : 3 point
1.6 PC Server & PDC installation
1.7 Communication Driver installation and configuration:5 points
1.8 InSQL & Active Factory installation and configuration : All tags
1.9 Engineering Documentation

2. FDC System Deployment (Manufacturing Information Management System)

2.1 Business Process Analysis
2.2 Database Analysis and Design
2.3 Deploy module for manual data entry and automatic data capture
2.4 Deploy data browser user interface
2.5 Deploy user interface to manage capturing schedule
2.6 Facility configuration
2.7 Oracle client installation and configuration
2.8 Development custom report and software application for managing report
2.9 Contingency plan
2.10 Engineering Documentation

Architecture
Client Operating System : Windows 2000/XP
Database : ORACLE 9i
Realitime/Historian Database : Wonderware InSQL Server 8
Reporting System : Crystal Report

Product and Implementation Features

• Enhanced Security (Security by User Entry Table, User Roles and Audit Trail)
• Automatic Data Captured directly from PMD and SMD machines as well as Lab Equipments
• Can be linked to other programs (Freeway, VIDES)
• Import-Export Data tools
• Built in Statistical Process Control (SPC) Tool
• Real-time data trending for Online data / process monitoring Historian database, enable historical analysis
• Integrated Reporting for PMD, SMD, Maintenance and Quality

Automatic Link to Plant Floor Data

FDC Module can capture data automatically from plant floor system (PMD and SMD) using real-time database, InSQL Server 8. This module will capture the raw data or aggregate data and insert into MPCIS database in customizable interval time. The green cells are indicated data captured directly from plant floor in real-time manner.

Statistical Process Control
FDC provides built-in Statistical Process Control (SPC) tool. SPC provides the ability to determine if a process is stable over time, or, conversely, if it is likely that the process has been influenced by “special causes” which disrupt the process. This tool provides pre-defined and customizable reports for analyzing data using SPC. SPC rule analysis such as Cp, Cpk, UCL, LCL and violated data from SPC rules is built in this tool. It also provides features to customize the color and the marker of point each time this point violate the rules.

Maintenance Reports
Type of Maintenance reports and analysis provided by FDC are:

- Machine Availability
- Machine Breakdown
- Machine Condition
- Machine Reliability

Quality Reports

The most powerful of FDC functionalities is the ability to calculate, analyze and provide reports for Quality area. The pre-defined reports of Quality are built in this application, such as:

- MQI (Daily, Monthly, Quarterly, MAA, Performance, Analysis by Parameter, Detail Analysis)
- PQI (Monthly, Quarterly, MAA, Performance, Analysis by Parameter)
- RQI (Monthly, Quarterly, Six Months, Performance, Analysis by Parameter, Penalty Point)
- COPS (Daily, Monthly, Performance, Detail Analysis, etc)
- Visual Defect Information, Visual Quality Number

The quality analysis is working on line and near real time, after new data from plant floor updated, the system is also capable process the data and display the reports.

SMD Reports

FDC is equipped with pre-defined reports of SMD area which are:

- Breakdown Record
- SMD COPS Yield
- Dust Monitoring
- Machine Output
- Machine Reject
- Material Waste
- Winnower Reject

PMD Reports

FDC is equipped with pre-defined reports of PMD area which are:

- COPS
- Efficiency
- Heavies
- PSD Trend
- Padding
- Yield