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Smithfield

Ignition SCADA Programming

A project designed  to evolve over time, provide additional data services, and to be used by a growing number of users. 

Challenge

Smithfield Foods required a real-time SCADA system to monitor Overall Equipment Effectiveness (OEE) at their Wilson, NC bacon processing facility, which uses diverse OEM equipment. This system needed to track metrics like throughput, downtime, yield, and uptime, with automated shift reports and visual displays.

Solution

Hallam-ICS implemented an Ignition-based SCADA system to aggregate and display production data, integrating Rockwell PLCs and MySQL and SQL databases. Custom dashboards enabled real-time monitoring and automated reporting.

Project Overview

Project Cost:

Project Duration:

 

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Results

The SCADA system improved operational visibility and provided actionable insights, enabling Smithfield to optimize performance, reduce downtime, and enhance production efficiency.

  • Data Integration: Aggregated performance data, including throughput, downtime, maintenance causes, and yield, from multiple OEM systems.
  • Real-Time Display: Provided real-time OEE data on large manufacturing floor displays, tracking against shift goals for better visibility.
  • Data Archiving and Reporting: Stored production data for detailed reporting, including:
    • Downtime events
    • Daily and shift yields
    • Historical trends
    • Total uptime
    • Throughput

Project Team

Chris Groen
Chris Groen
Project Manager
Rick Harper 225 x 225
Rick Harper
Project Manager
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