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Managing Realtime Process Data

Sector: Manufacturing (Carbon Black )
Client Details :
Thai Carbon Black, Thailand (TCB)
Thai Carbon Black (TCB) is part of the multinational Aditya Birla Group and is the largest producer in the world of carbon black from a one point location-at Angthong, about 100 kms from Bangkok, Thailand. TCB produces various grades of furnace carbon black and makes deliveries to customers spread over the world
Business Challenge

TCB required a Technical Process Management system, which handled its voluminous process data in Realtime of its rapid and interlinked process flow at High accuracy and security levels.

Technology & Systems used

PowerBuilder 6.0, PowerDesigner, ObjectCycle, Sybase 11.9.2, Windows 95/NT, Sun Solaris server, Foxboro's Data for Windows, TideStone Formula One and First Impression ActiveX components, Dolphin hand held bar code scanners, serial port communication software for Toledo weigh bridge developed in Inprise Delphi

Solution/Project

Implement a Real time Process Information Management System. Capture the production and quality related data to facilitate decision making related to plant operations. Automate the warehouse processes and inventory management system

TCB generates volumes of process related data in real time. This data scales to volumes ranging up to a transaction rate of 2000 per hour, necessitating capture of around 2000 fields, all in real time. The process flows at a rapid rate and is inter linked. TCB required a system, which handled all process data at high accuracy levels. The security within the application was necessitated by the fact that there were 40 users operating the system at various shifts, which involved modification, archival, authentication of data. Warehouse automation was central to providing a feed back to the entire application. Since the floor operators were using IT not very frequently, the entire application needed to be designed with utmost user friendliness.

The application comprises of over 300 tables, over 150 data capture screens, 120 Web enabled reports and involve integration with Weighbridge, bar code scanners and DAS.

The application included the following modules:
Production Process Control System, Warehouse Management System, Quality control system and Utilities Management System

Result/Benefits

An Efficient and highly scalable Process management system
Contract Executed by:
SystemLogic Solutions Ltd, India - a Helios and Matheson subsidiary
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