Transforming Operational Reliability

After consultation and plant optimization services, the HMI was identified as the primary source of operational issues, prompting the proposal for an HMI migration project. The project involved a full migration of the HMI to the Ignition Perspective platform on new, modern hardware, replacing unreliable software and obsolete server hardware. This included visualization, tag historian, and full SCADA functionality while retaining the existing PLC and controls, enhancing system reliability and maintainability.

Migrating to a more industry-standard HMI platform would facilitate easier troubleshooting, configuration, and future scalability, addressing the limitations of the previous proprietary system. The new system is non-proprietary, widely supported, and well-documented, enabling the client and local integrators to provide effective support, faster problem resolution, and reducing dependence on a single provider.

The mill valued having a knowledgeable local integrator for rapid support and quick troubleshooting during critical downtime. This relationship was a key factor in project success.

The plant has experienced zero unplanned downtime over the six-month period following the commissioning of the new server hardware and Ignition HMI, a significant improvement over the previous months. In the six months prior to commissioning, the plant experienced up to 270 hours of unplanned downtime related to server and HMI issues. The improved operational stability, system reliability, and support responsiveness allowed them to meet increased order demand.

This stability lays the foundation for planned plant expansion, including the addition of new lines and capabilities and increased production capacity

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