Quality monitoring, traceability and reporting were challenges at the Rojana plant.
F&N also is
required to keep product quality documentation until the end of the product’s
shelf life, which is typically 2 years.
Before Process Nexus II, it was easy to make
mistakes during the process of reviewing these parameters since the reports
were all hand written. It also was a
time consuming process, with a high workload that involved developing the QA
documentation of the processing line.
“There were about 40
reports per day, which included raw material receiving, processing control
sheets, filling and packaging, as well as cleaning operation control sheets,”
Boonnam, quality assurance manager at F&N. “Process Nexus II has helped to solve this
problem by reducing the quality traceability process time to only one minute.
Without Process Nexus II, it would takes us more than four hours to complete
one traceability report.”
Prior to the Process Nexus II system, when quality
parameter deviations were detected, operators had to manually trace the
information in the paper-based operations sheets filed in the archive room. This took countless hours of manpower time
and effort to trace the root cause of the problem.
To resolve the manual input of data, the new software
system features Wonderware Historian which is a high-performance process
historian, capable of electronically storing huge volumes of data generated
from F&N’s facility. Historian easily retrieves and securely delivers
information to desktop or mobile devices, enabling the company to analyze
processes anywhere at any time.
Historian works in conjunction with Wonderware
InTouch allowing critical process data to be captured and available for
troubleshooting and process analysis when necessary.
“After the Nexus II
implementation, it is very convenient to summarize and consolidate the plant
data,” said Sitthichai Sribunyapirat, F&N production manager. “We are now able
to collect product traceability information for both the upstream and downstream
functions of our process in real time."
easily connects to a wide variety of 3rd party products
There are several reasons why Wonderware software
solutions were chosen by F&N Dairies.
First, was for its easy connectivity with other devices in the
plant. With so many processes and
equipment types in place at F&N Dairies, the Wonderware software solutions
provide easy connectivity with the other industrial automation devices,
computers and lab measuring instruments currently at F&N.
Total Cost of
Ownership is lower than most competitors
The second reason is the lower total cost of
ownership for system upgrades which was provided by Wonderware software
solutions. When evaluating Wonderware, F&N
compared it with other software applications, and the total cost of ownership of
Wonderware was comparatively lower than its competitors.
software is Windows-based, it provides an easy upgrade path,” Roongruang, said. “When Microsoft upgrades a version of
Windows, or Wonderware issues a software upgrade, the Process Nexus II software
is automatically upgraded over all processes and locations.”
II gives F&N Dairies 100% FTQ
With Wonderware MES Software/Operations solutions,
F&N Dairies is able to track raw materials inventory more efficiently. The solution helps the company to manage,
execute and document production operations information during work order
execution, which includes bills of material and equipment set point specifications,
inventory tracking and collecting product genealogy for lots and sub lots, as
well as consumed and produced materials.
The plant also achieved “100% First-Time Quality,” which
is a lean metric that indicates what products are manufactured correctly the
first time, without the need for inspection, rework or replacement.
Investment within 1 year
Using Wonderware MES Software/Operations Solutions,
F&N increased its operational efficiencies, reduced production errors and
quality losses, as well as increased product yields. F&N productivity also has
risen through rapid inventory turns, reduced production lead times and faster
new product introductions.
Process Nexus II is also responsible for Product
Inventory Control. After production is
completed, the finished products are typically stored in a warehouse where they
await transport. After the implementation of Process Nexus II, products are
dispatched early and sent straight to the container vans, ready for transfer to
the ports for distribution, bypassing the warehouse altogether.
"With this system, F&N has
reduced inventory in our warehouses, created cost savings, and achieved payback
from our system investment within one year,” Khwahan said.
The trust of
F&N Dairies in the capability of Wonderware Ecosystem Partner Sagitate is
evident in its long and deep collaboration
success of the Process Nexus II system at F&N Dairies was thanks to a small
village of experienced engineers both at F&N and Sagitate. F&N has benefitted from a seasoned team of
Wonderware consultants, architects, and project managers that are uniquely
qualified to provide design engineering and product specialist services that
address all aspects of supervisory control, operations and asset management
Process Nexus II, the Rojana plant of F&N Dairies, Thailand, enjoys
significant savings in production, logistics and inventory costs, making the
company well placed to meet the needs of its business goals now and well into