"We want our lines integrated from beginning to end so that if there's a stoppage, you don't have people walking from machine to machine to shut things down while you understand and correct whatever caused the stoppage," says Lydon. "If everything is integrated—most likely by way of an Ethernet connection—the signals to shut down would move automatically up the line."
Once the packaging lines are networked, Lydon's next challenge will be to extend connectivity into MES and ERP layers. He's the first to admit he'll need to do some serious research and learning before he's ready to implement such a thing. But he knows the benefits are there to be had.
"With that kind of access to real-time data, you can increase efficiencies by looking at your system as a whole," says Lydon. "It also helps reduce the chance for inaccurate or unreliable data due to human error."
A crucial prerequisite, he points out, to implementing any kind of MES or ERP connectivity is the task of quantifying and justifying its cost. "Upper management wants to know the specifics on payback," he says. "And the payback has to come from gained productivity. Part of the gain may be managerial in nature. Instead of managers looking at pieces of paper all the time, they'll be able to pull up information right on the computer or HMI screen. That's going to start freeing them up to look at other projects."
