Case Study: Integrating Database Automation in The Timber Industry 

Automating Database processes for production environments can provide significant benefits for manual, labor-intensive operations. Embry Automation & Controls has considerable experience partnering with timber industry companies to provide valuable solutions that increase manufacturing efficiency and integrate automated database solutions.

Overview

This case study highlights one of our timber industry customers who manufactures railroad ties. We developed and implemented a system upgrade for their operations’ grading and processing portion. 

‍

Challenge:  

• Operator data entry errors
• Downtime and admin time due to manual entry and information delivery
• Inaccurate & unreliable data collection
• Outdated and unsupported system currently in use
• No back-up of data

‍

Solution:

• Upgrading to a new computer with battery and NAS back-up
• Replaced manual push-button operator station with a modern touch screen grading application
• Adding a SQL Database for data storage
• Developing a custom Access application for office staff

‍

Results:

• The data system is safe from data corruption due to power loss
• Operators are no longer required to hand deliver written reports to office staff across the facility
• Manufacturing controls supported by a PC-based interface with remote support capabilities
• The office staff has access to custom reporting built to customer specifications
• Data collection is accurate
• Operators have digital ticket creation and entry
• Managers have better visibility of shift reports and production

‍

Challenges & Objectives

The customer’s production processes proved to be labor-intensive, and key production data was prone to a chain of human errors during data entry. Every time an operator would receive a load of ties to grade and process, they would first have to fill out data manually in a provided form with information such as the number of ties in that load. During the production process, the operator would have to manually record the grade of each tie as it passes through the grading booth and then be processed in different production streams based on the grade given. When that group of ties had been graded, the operator would have to manually total the completed grading processing information. A similar process was required for recording production downtime, where the operator would have to manually record the downtime and provide totals at the end of the shift. At the end of a shift, this manually recorded information would be submitted to production to be processed by office personnel, which required them to verify, key in, and submit the data into their database. 

There were several problems with this workflow that we were able to address. The numerous instances of potential operator errors were an issue that could be addressed and provide significant improvement in their production processes. Implementing upgraded industrial control components and automating data acquisition would optimize the production process and reduce the amount of downtime previously required to do the manual data recording. The long-term benefits of these upgrades would present themselves as increased operational efficiency and output as well as reduced man-hours for the processes that can be automated, freeing up the operation’s employees to focus on more important tasks!

Our Solution

To solve our customers’ issues with their process and data acquisition, we built a custom-tailored automation and database solution in their timber grading operations to optimize and simplify the data management process. 

The first part of our solution focused on functional control of the manufacturing system. We Installed a new, high-resolution touchscreen human-machine interface (HMI) in the operator booth that utilizes FactoryTalk View Studio SE, a software created by Rockwell Automation. Utilizing this powerful software, we created several screens for the operator to run and monitor the grading and production process. We provide visualization for material tracking through the process as well as maintenance-specific troubleshooting screens that greatly reduce downtime. Utilizing our single-button sequential startup and shutdown provides a simple and hassle-free system operation. Some of the noteworthy interfaces we will go into more detail below include the ones used for creating new loads, starting/completing loads, logging production downtime, and logging lumber grades.

‍

Load Creation – Our system provides the flexibility for receiving personnel or production operators to create new loads. If loads have not been pre-entered by receiving, the operator can enter various points of data, such as the mill it is from, and the number of ties included in that load. The operator can select the mill from a pre-programmed drop-down list that contains their suppliers, reducing the chance of typing errors and eliminating hand-written data recording. Additionally, when completing a load, there are pre-programmed checks in place that will prevent the submission of data if any of the data entered is invalid, such as if that load has already been created. 

Grading – The operator, or Tie Inspector,  is now equipped with a streamlined and easily trainable process for grading. The operator can select from a drop-down list containing all the created and uncompleted loads in the database. Once the proper load is selected, the operator can start processing and grading individual ties. Grading is done by touching one of the multiple buttons on the HMI screen that corresponds to the grade the operator assigns as ties move through the inspection zone. The overall load count is continuously updated as the ties are processed until the load has been completed, which the operator confirms by touching a dedicated load complete button. This triggers an automatic delivery of production data for that load to the proper database and resets for the next allocated load.

Downtime –Downtime is the single most impactful variable on production margins. In order for maintenance to correct downtime events, it is necessary to catalog where time is being lost. During an active shift, if a tie has not been graded in the allotted time, an automated pop-up screen will prompt the operator to record a reason for downtime. The operator selects from a pre-programmed list of downtime codes, time for the event is then recorded automatically upon the next graded tie and uploaded to the database. This data is collected and collated in order to build reports for production management staff.

‍

The second part of our solution was implemented in the production management offices of the operations site. By implementing an SQL database and Access application for use by the production planning, we were able to accomplish the following:

• Automatically acquire load reports from production. 
• Automatically receive downtime reports as they are submitted.
• Edit individual load information. 
• Enter new suppliers for the operators to select when entering job details.

Together, the solutions allowed operators to digitally input information, and the information is easily accessible to office personnel and vice versa. 

The Results

Our customer is happy with the improvements we have provided, clearly recognizing the impact these solutions have had on their daily operations. Overall, we accomplished the following:

• Eliminated the likelihood of costly data entry mistakes by eliminating analog data streams in the production process. 
• Streamlined the operation by integrating modern HMI interfaces to process and grade the railroad ties more accurately.
• Reduced downtime by streamlining the process by which it is recorded between loads, increasing overall production over each shift.
• Optimized the delivery of production data to production management and planning, which drove an increase in production output over time due to improved data acquisition and accuracy. 

This is a good example of how improvements at each stage of an operation can stack to provide major improvements to an overall system. Embry Automation & Controls has considerable experience working with our customers to understand their current operations processes and goals to provide a custom solution designed to meet or exceed expectations. If you are interested in how we can provide a similar result to your operations, please don’t hesitate to reach out to our experts and contact us today.

‍