Manage your production in real time

PlantSuite allows to reach one of the most industry challenges: Consolidate informations from many sources in an integrated system, for production management and decision making in real time, with ease and low total acquisition cost.

PlantSuite Chart with System Features

What is PlantSuite?


It is a production management modular system and plant resources, consolidate field data, building web-based reports.



PlantSuite collects data from control systems and electronic appointment, providing performing reports and production by order, batch and shift, among other variables.


The system shares plant information between every envolved person, according to profile access, facilitating decision making for management and operation.


Nowadays, PlantSuite platform is composed by the following modules: Historian, Weighing and Fractioning, Audit Trail and Alarms.

  • Historian
    PlantSuite Historian Module
  • Weighing
    PlantSuite Weighing Module
  • Audit Trail
    PlantSuite Audit Trail Module
  • Alarms
    PlantSuite Alarms Module
  • Production attendance and real time reports
  • Performance indicators: OEE, Efficiency, and others
  • Quality data integration with produced batches
  • Stop causes identification and production losses
  • Products registry, equipments, recipes and specifications
  • Micro ingredients weighing and fractioning
  • Consumption accounting and production by order
  • Audit Trail and electronic signature
  • Results analysis by work teams
  • Variability reduction and operational costs
  • Production history and traceability
  • Alarms management
  • Microsoft .NET platform, MS SQL Server database, web services, XML and OPC
  • Process model and plant information flow according ISA-88 and ISA-95 rules,
    to guarantee integration and funcionality
  • System access from any network node using browser
  • Modular system with implementation in steps as demand
  • Possibility of gradual investment and planning
  • Harnessing existing structure
  • Minimum operational training
  • Does not require license by user
  • Centralized administration
  • Variability reduction and operational costs
  • Multi-language: portuguese, english, spanish and others
PlantSuite demo in the computer screen

Historian


PlantSuite Historian is a module that allows personalized historical reports
and charts creation, with collected data during production.

PlantSuite Historian demo fluxogram

Data collected from the plant are stored
in database and displayed in browser for the user.





Efficient data collection


Store process variables like temperature, level, weight, pressure and others,
through custom events.



  • Collect data by variation, time interval and process events
  • Local buffer in case of database unavailability
  • Access to the system of any network node by browser
  • Easy variables register and organized by groups
  • Possibility of gradual investment and planning
  • Variables search and data collect from OPC servers
  • Advanced data compression algorithm, reducing disk space
  • SQL Server database, easy access and integration to other applications




Custom Reports


Create your own reports in just a few clicks in a easy and intuitive way, analyse your
process through precious charts and tables and share information with your
team and customers.



  • Real time and historical reports
  • View reports in charts and custom tables
  • PDF and excel exporting
  • Statistics functions like standard deviation, average and others
  • Define acess and edit permissions to the reports



Performance

Load long periods reports and big data volume in just a few seconds, thanks to the advanced
sampling algorithm and parallel processing that reduces the reports loading time.



Security

Define acess and edit permissions to the reports by users and groups.

PlantSuite Historian sine wave chart demo screen
PlantSuite Historian sine wave chart demo screen

Weighing and Fractioning


PlantSuite Weighing and Fractioning is a module for division and
rastreability of micro ingredients for production.

PlantSuite Weighing and Fractioning demo fluxogram

The system covers since the receipt of raw material
in the factory to the rastreability of the final product package.




It is necessary to have a server in the factory where PlantSuite will be installed, system has built interfaces for labels printing, bar code scanning and weighing-machines (serial and ethernet).





Main system features are:


  • Micro ingredients weighing and fractioning
  • QR code labels printing or conventional bar code
  • Raw material bar code reading on the receiving
  • Rastreability report with batch information, raw material,
    weight, weighing times and others
  • Package rastreability


Rastreability Report

  • Production order / Batch
  • Operator
  • Weighing Date/Time
  • Raw material
  • Batch supplier
  • Weight
  • Integration with Historian module to obtain process variables charts during production
PlantSuite rastreability report chart demo

Production Order

The system has the ability to get production orders generated by ERP systems (eg: SAP). User can select the production order and start the process through HMI or mobile device.

Production order demo screen

Weighing and Fractioning

Weighing interface, conection to RS-232/ethernet weighing-machines, QR code or conventional bar code reading, products order and weighing validation, protection for overweight and label printing.

PlantSuite Weighing and Fractioning demo chart

Audit Trail


PlantSuite Audit Trail is o module that allows the register and the viewing of Operator Actions,
Changed Parameters and Events/Alarms log from machines and prodution lines.

PlantSuite Weighing and Fractioning demo fluxogram

System captures necessary data from DCS,
HMIs and PLCs for reports generation and printing.




Audit Trail module uses a SQL Server database for securing data store, generates web reports and meets the requirements of RDC 17/2010 (ANVISA)
and 21 CFR Part 11 (FDA).





Main system features are:


  • Alarms/Events log
  • Operator Actions register
  • Changed Parameters storage
  • PDF exporting
  • Custom queries


Alarms and Events

Stores all alarms and events occured in the machine or process, generating reports where queries can be done
trough time filters (date, month, year, interval), by tag, by area or alarm/event type.


PlantSuite Alarms/Events log demo table

Operator Actions

Stores all actions performed during system operation, like: valve opening and closing, equipments on/off. Information stored are date, hour, user name who executed some action and everything changed, allowing queries through filters from any items.


PlantSuite Operator Actions demo table

Changed Parameters

Stores all changed parameters and setpoints, showing old and new value, editing responsible and performing date/time. Is also requested a justified for parameter changing, helping occurences investigation.


PlantSuite Changed Parameters demo table

Alarms


PlantSuite Alarms is a module that generates reports, performance
indicators (KPIs) and sends alert messages (email and SMS)
to registered users.

PlantSuite Alarms demo fluxogram

System administrators can configure users,
alarms, groups, messaging and
access to reports.




The collection of alarms and process variables can be through hardware or a installed
component on a server with access to operating systems (SCADA or DCS) and internet
connection. The collected data are sent to the central server management and
messaging. The technological structure for storing information is based on
the concept of cloud computing.





The main functions:


  • Managing users and groups
  • Alarm Management
  • Alarm Management Group
  • Report alarms and process variables
  • Performance indicators (KPIs)
  • Alarm management as EEMUA 191 and ANSI/ISA-18.2 standards


Performance indicators (KPIs)


The PlantSuite Alarms generates the following indicators:


  • Average alarms per hour per operator
  • Rate and peak alarm
  • Percentage of instability
  • Frequently Alarms
  • Noisy alarms
  • Continuous alarm
  • Distribution of alarms by priority and area



Frequently Alarms

This analysis brings immediate results. The "top 20" may be responsible for 50% of total alarms therefore should have priority in the projects of rationalization. The report is a column chart containing the 20 most frequent alarms with user-selected filters: period, shift, and priority area.

PlantSuite Most Frequently Alarms demo

Alarm Distribution

Alarms are displayed in the distribution graph format customized by the user. The standard analysis system is the distribution of alarms by priority and area.

PlantSuite Alarms Distribution chart

Rate peaks alarm

This indicator shows graphically the peaks of alarms in the selected period, enabling the user to verify the periods of instability of the plant or the occurrence of noisy alarms. The analysis is made at intervals of 10 minutes by plotting a bar for each interval of more than 10 alarms.

PlantSuite Rate Peaks Alarms chart

Typical Architecture



PlantSuite Typical Architecture




PlantSuite Benefits



  • Production management in real time
  • Ease of access to information for decision making
  • Significant improvement in efficiency and quality processes
  • Reducing costs and increasing productivity
  • Substantial increase agility in operations
  • Greater visibility and control of production
  • Reduction of paperwork

Contact



IASTECH Automação de Sistemas Ltda.
Rua Sansão Alves dos Santos, 76 - 4º Andar - Brooklin Novo - São Paulo - SP - CEP: 04571-090