- To Find an internal solution that would raise productivity levels for the customer and to tackle the external challenges they were facing due to market conditions
- FT Batch Solution ( alleviated Star Union's areas of concern such as equipment control, recipe management, equipment allocation, batch execution and most importantly, data collection and management)
- Plant production increased to 100%, production increased to 2,500 tonnes month from 1,200 tonners per month.
- Production waste reduced to Zero.
- Reduced work in process by 5%.
- Average Overall Equipment Effectiveness became 85%.
Singapore-based Star Union Engineering Pte Ltd is an equipment manufacturer in the paint and ink business that offers mixing, grinding, process automation, production plant design, and project management.
Star Union needed to find an internal solution that would raise productivity levels for the customer and help them tackle the external challenges they were facing due to market conditions. The combination of workforce shortages, changing market demand, increased competition and the effects of digitalization were all taking a toll on their business.
To raise productivity levels, they required a solution that would maximise their capacity utilisation and increase their speed of work. However, it needed to be foolproof and allow them to control the entire system and ensure stable communication between devices while complying with the standards of ISA88.
Automating processes from start to finish
Star Union approached Rockwell Automation for support and decided to utilize FT Batch Solution. FT Batch Solution alleviated Star Union's areas of concern such as equipment control, recipe management, equipment allocation, batch execution and most importantly, data collection and management.
Following the installation of FT Batch from Rockwell Automation, Star Union’s equipment was configured, and their processes were automated. Unlike third-party solutions that require equipment to be synchronized one by one, FT Batch Solution connects all equipment simultaneously, saving Star Union engineering time in the implementation process.
With the installation of the FT Batch Solution, the user now had self-generated options such as ‘abort’, ‘common logic’ and ‘reset’ in their PLC system. Other add-on features also include ‘patching’ and ‘drive’. The user was able to train their employees and get them up to speed on the new processes within two days, as executing FT Batch only requires basic computer knowledge despite the software being highly intelligent.
Driving results through intelligent solutions
Following implementation, the user was able to execute multiple batches concurrently. They were now producing an average of 2,500 tonnes per month instead of just 1200 tonnes per month previously and their plant’s productivity levels increased by 100%. Given that the number of staff required to work on these processes had now halved, they were able to allocate their resources to other areas of the company. Additionally, their production waste was zero as they now had the option to put processes on hold to reduce errors in their production. Power consumption was at 80 kg/kWhr whereas they would be using 60 kg/kWhr without FT Batch Solution. Average Overall Equipment Effectiveness was 85%.
FT Batch Solution fulfilled Star Union's customer goal of making their operations faster, better and more cost-efficient and allowed them to respond to, and resist, external challenges.
"Often, many businesses believe that they can save costs by writing their programmes. However, they fail to realize that engineering the programme on their own would be incredibly time consuming and may not provide the desired results. The benefits of implementing a solution such as FT Batch far outweighed the advantages of taking on such a project ourselves.
The new connectivity within our plant has not only resulted in apparent improvements in productivity, but it provides us with insightful data that helps us to ensure we stay on track as well as identify areas for improvement. In working with Rockwell Automation, we can help provide a comprehensive programme from start to finish.” - Mr. Ow, Managing Director