How Migration to Modern DCS Cut Development Time in Half

Migration to Modern DCS Cut Development Time 50%

Advanced process automation and machine safety on a single platform helped a household products maker also reduce spare part and training costs.

Yuhan-Kimberly was established in 1970 as a joint venture between Yuhan-YangHang and American company Kimberly-Clark. Yuhan-Kimberly was the first company to introduce several different personal care products that now are an important part of everyday life in South Korea. Its Kimcheon plant is Asia's top personal hygiene paper manufacturing facility, producing such household supplies as tissues, toilet paper and kitchen towels.

With the rapidly increasing demand for bathroom paper towels, it no longer was efficient or effective to import raw materials from the United States for processing and packaging in the Kimcheon facility. Yuhan-Kimberly needed to produce the raw materials in-house and decided to undertake a project to move the towel machine in the U.S. facility to Kimcheon.

This would require a major upgrade. Within this production process, Yuhan-Kimberly was running an outdated legacy distributed control system (DCS). Replacement parts were a challenge to find, and it was almost impossible to obtain the updated functions needed to improve efficiency to levels Yuhan-Kimberly wanted, such as additional machine safety options and a multidiscipline system that included a modern process solution and safety control.

To complicate the situation, to meet production targets, the new system migration would need to be completed quickly, with no downtime.

Control Systems and Architecture Modernized

Yuhan-Kimberly began working toward replacing the facility's legacy control systems and modernizing the architecture to increase productivity and safety. The company wanted an integrated system that would provide full production line and recipe capabilities and solve quality and consistency issues that had been problematic with the legacy DCS. Because of the old system's complexity, it was important that the new installation be user-friendly.

The PlantPAx modern DCS delivers a unified process and discrete solution for Yuhan-Kimberly.

Figure 1. The PlantPAx modern DCS based on the Rockwell Automation Integrated Architecture system in the Kimcheon, South Korea factory delivers a unified process and discrete solution for Yuhan-Kimberly.

Yuhan-Kimberly secured bids from Rockwell Automation and other automation suppliers for converting the system, which included controller, human-machine interface (HMI) and machine safety. It also analyzed the applications used on the legacy system and considered how those applications could be designed, migrated, installed and commissioned on a Rockwell Automation platform.

The company chose to go with the PlantPAx® modern DCS, which is based on the Rockwell Automation Integrated Architecture® system and delivers a unified process and discrete solution (see Figure 1). For Yuhan-Kimberly, the process automation platform incorporates control technology, HMI software for visualization into each application, machine safety devices for operators and communication interface applications to link the systems with EtherNet/IP™.

Integrated Control Platform

The new process control system centers on the Allen-Bradley® ControlLogix® programmable automation controller (PAC). Unlike traditional controllers, ControlLogix PACs provide multidisciplined control leveraging development tools, a network protocol and service-oriented architecture, making it a fully integrated, scalable control platform that can be used throughout Yuhan-Kimberly's plant.

The modern DCS has experienced zero downtime since the installation completion date.

Figure 2. The modern DCS has experienced zero downtime since the installation completion date, saving two months of the usual four months of implementation time.

The core advantage of this is a single hardware and software solution that includes an Integrated Architecture-based modern DCS, PlantPAx and machine safety control via a single industrial network: EtherNet/IP.

To accelerate the migration process, maintain consistency and reduce installation time, the customer relied on the Rockwell Automation Library of Process Objects. This Library is simple and convenient to use and allows operators to minimize system deployment and test time. As a result, this solution improved production efficiency, expedited the start-up process and improved time to market.

The domain expertise of the Rockwell Automation Global Process Technical Consultant (GPTC) team provided training to Chumdan FA, Rockwell Automation Process Solution Integrators (SI) engineers, and also to Yuhan-Kimberly operators, helping them acclimate to the new system and use its features. This team led Yuhan-Kimberly through its well-defined and strategic technology migration path.

Early Implementation Completion

The Rockwell Automation Library of Process Objects shaved two months off of the implementation time, so operators installed the PlantPAx system ahead of schedule (see Figure 2). They immediately took advantage of easier operating procedures. For example, instead of checking the Logic programs one by one, a legacy system requirement, operators were able to check and change the machine's operating condition and view the interlock status safely via the faceplate.

The smooth migration completed on the single platform reduced spare parts and training costs. Additionally, the PlantPAx modern DCS has reduced the total cost of ownership (TCO) while satisfying the customer's request for improved machine safety.

Learn about Rockwell Automation Household and Personal Care Solutions.

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