ICONICS Case Studies Customer Success Story - PRAKAB a.s.

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	Customer Success Story - PRAKAB a.s. ICONICS

Customer Success Story - PRAKAB a.s.

ICONICS

Technology Category	Analytics & Modeling - Process Analytics Application Infrastructure & Middleware - Data Exchange & Integration Application Infrastructure & Middleware - Middleware, SDKs & Libraries
Applicable Industries	Electronics
Applicable Functions	Discrete Manufacturing Quality Assurance
Use Cases	Manufacturing System Automation Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration
Challenge	PRAKAB a.s., one of the largest producers of wires and cables in the Czech Republic, embarked on an extensive investment program to modernize its plant and increase production. This involved the launch of new cable production lines and the reconstruction and maintenance of management systems for existing production lines. The company's manufacturing processes involve multiple machines, including extruders, decoilers/unwinders, rewinders, heating/cooling devices, and PVC granulate dosers. An average of 300 I/O points are incorporated into each of PRAKAB’s 15 cable and wire manufacturing lines. The company mainly uses Siemens S7-300 PLCs that provide data to the SCADA system over PROFIBUS and Ethernet networks via OPC communication standards. Read More
About Customer	PRAKAB a.s. is one of the largest producers of wires and cables in the Czech Republic. The company manufactures power and communication cables as well as building wiring. In a bid to modernize the plant and increase production, PRAKAB recently launched an extensive investment program. This involved putting new cable production lines into operation and undertaking the reconstruction and maintenance of management systems for existing production lines. The company's manufacturing processes involve multiple machines, including extruders, decoilers/unwinders, rewinders, heating/cooling devices, and PVC granulate dosers. An average of 300 I/O points are incorporated into each of PRAKAB’s 15 cable and wire manufacturing lines. Read More
Solution	Systems integrator, ADAX, Ltd., recommended the GENESIS32™ Web-enabled, OPC-integrated HMI/SCADA suite to manage PRAKAB’s production lines. GENESIS32 Enterprise Edition is now tied to each production line, while GraphWorX™32 appears on each of PRAKAB’s application displays, providing facility-wide status and details on individual machines. AlarmWorX™32 provides early warning to operators if set process parameters are exceeded and helps operators determine a root cause in the event of any process failure. TrendWorX™32 assists in the analysis of production quality. PRAKAB also utilizes GENESIS32’s recipe capabilities, designed to integrate with VBA. Reports are conveniently stored in Microsoft Excel files and SQL databases. The company uses DataWorX™32 software for OPC data aggregation, bridging, redundancy, and tunneling. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Process Analytics

Application Infrastructure & Middleware - Data Exchange & Integration

Application Infrastructure & Middleware - Middleware, SDKs & Libraries

Applicable Industries

Electronics

Applicable Functions

Discrete Manufacturing

Quality Assurance

Use Cases

Manufacturing System Automation

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Challenge

PRAKAB a.s., one of the largest producers of wires and cables in the Czech Republic, embarked on an extensive investment program to modernize its plant and increase production. This involved the launch of new cable production lines and the reconstruction and maintenance of management systems for existing production lines. The company's manufacturing processes involve multiple machines, including extruders, decoilers/unwinders, rewinders, heating/cooling devices, and PVC granulate dosers. An average of 300 I/O points are incorporated into each of PRAKAB’s 15 cable and wire manufacturing lines. The company mainly uses Siemens S7-300 PLCs that provide data to the SCADA system over PROFIBUS and Ethernet networks via OPC communication standards.

About Customer

PRAKAB a.s. is one of the largest producers of wires and cables in the Czech Republic. The company manufactures power and communication cables as well as building wiring. In a bid to modernize the plant and increase production, PRAKAB recently launched an extensive investment program. This involved putting new cable production lines into operation and undertaking the reconstruction and maintenance of management systems for existing production lines. The company's manufacturing processes involve multiple machines, including extruders, decoilers/unwinders, rewinders, heating/cooling devices, and PVC granulate dosers. An average of 300 I/O points are incorporated into each of PRAKAB’s 15 cable and wire manufacturing lines.

Solution

Systems integrator, ADAX, Ltd., recommended the GENESIS32™ Web-enabled, OPC-integrated HMI/SCADA suite to manage PRAKAB’s production lines. GENESIS32 Enterprise Edition is now tied to each production line, while GraphWorX™32 appears on each of PRAKAB’s application displays, providing facility-wide status and details on individual machines. AlarmWorX™32 provides early warning to operators if set process parameters are exceeded and helps operators determine a root cause in the event of any process failure. TrendWorX™32 assists in the analysis of production quality. PRAKAB also utilizes GENESIS32’s recipe capabilities, designed to integrate with VBA. Reports are conveniently stored in Microsoft Excel files and SQL databases. The company uses DataWorX™32 software for OPC data aggregation, bridging, redundancy, and tunneling.

Impact #1	The new control system has increased the reliability of connected equipment.
Impact #2	The system has reduced production downtime.
Impact #3	The appearance of unified operator panels on all production lines has reduced staff training time.

Impact #1

The new control system has increased the reliability of connected equipment.

Impact #2

The system has reduced production downtime.

Impact #3

The appearance of unified operator panels on all production lines has reduced staff training time.

Benefit #1	12 of 15 of PRAKAB’s cable and wire production lines have been outfitted with the updated management/control system.

Benefit #1

12 of 15 of PRAKAB’s cable and wire production lines have been outfitted with the updated management/control system.

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Overview

Customer Success Story - PRAKAB a.s.

Operational Impact

Quantitative Benefit