Ignition Aids Major Growth for Food-Industry Leader
SugarCreek is a very large, dynamic, growing food manufacturer which requires plant-floor data to allow Operations to identify and solve problems across six manufacturing sites. Over the past few years, Ignition has enabled SugarCreek to collect and analyze new levels of data with significant results including cost savings and improved efficiency. Ignition is also a big part of the company’s continuous improvement processes, and SugarCreek’s increased emphasis on OT-IT convergence.
In 2015, SugarCreek management identified the need to utilize OT-level data more effectively to enable effective visualization and problem-solving across the six manufacturing sites. The resulting project was built entirely in-house using one permanent engineer/manager and one intern. The project included waste water monitoring and control for two sites, refrigeration monitoring and control for three sites, utilities monitoring for two sites and MES monitoring and reporting for 15 production lines across five manufacturing facilities.
SugarCreek also uses Ignition for automated reporting for around 10 external databases. The intent is to connect all relevant data sources to Ignition for visualization, reporting, alarming and control — allowing SugarCreek managers to make data-driven decisions based on actionable, relevant data.
- More than 15,000 tags
- More than 250 windows
- 30-50 clients open at any given time
- More than 1,000 alarms
- 7 alarm notification pipelines
- More than 98 devices connected (CompactLogix (9), ControlLogix (53), MicroLogix (3), Modbus (12), Siemens S7300 (4), SLC (13), TCP (4))
- Standard Architecture, single gateway
- 10 SQL database connections
- 27 historical transaction groups
- Thousands of historical tags
- 44 reports (roughly half are scheduled)
After spending 21 years in various manufacturing engineering roles in the automotive industry, Dan joined SugarCreek, a privately held food manufacturing company, four years ago. In his current role, Dan leads the OT side of the Corporate Continuous Improvement (CI) team which includes engineering, IT, maintenance and operations personnel. All of the data and reporting for the CI activities comes from an Ignition project that Dan developed for data collection, visualization and reporting for five manufacturing sites.Created By:
SugarCreek is an innovative, diversified and flexible food manufacturer helping some of the industry’s largest and best-known companies develop Brandworthy Food Solutions. SugarCreek’s authentic culinary expertise helps drive innovation, and its in-house expertise in everything from food trends and marketing to packaging and logistics makes the company an ideal partner for new product development — including bringing scale to sous vide. SugarCreek employs more than 2,000 people in six manufacturing facilities, and serves clients across the U.S. and internationally.