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Manufacturing / ERP Integration

We really needed advice from a partner who understands our manufacturing process, and we got it from MAVERICK.”

— Satisfied Client High-Tech Manufacturing

Vertically Integrate your Enterprise

Manufacturers waste hundreds of thousands – even millions – of dollars year after year due to inaccurate and incomplete information about their operations. Immediate gains in many areas of a business can be realized by integrating your company’s ERP system with the operational systems to give the right people (and systems) the right data at the right time to optimize business decisions, reduce manual efforts and errors and improve overall operations.

For example, the inability to quantify material consumption quickly at the end of a production run or batch can:

  • Create delays in your supply chain
  • Add inventory costs
  • Increase labor costs
  • Add friction to your processes, and
  • Tie up working capital.

If your operation is not reporting material consumption automatically, then assumptions are likely being made to fill in the blanks based on the allocations defined in the bill of materials or recipe. These assumptions can create inventory inaccuracies resulting in excess material or stock outages which can stop production.

Many manufacturers address these issues via manual inventory checks and back flushing at the end of each run or batch, but this approach has critical inefficiencies:

  • Produces lags in your daily processes
  • Adds operating costs
  • Reduces accounting accuracy
  • Delays releasing orders if accounting procedures require the value of material consumed to be accurate before an order can be shipped, and
  • Ties up working capital in finished goods inventory.

The same idea also applies to quality specifications and quality result information. Next to safety, there is nothing more important than product quality. In an ideal environment, the master product quality specifications flow seamlessly from the ERP system to the production assets and personnel at the beginning of a production run or batch to ensure the correct quality parameters are matched to the product that is to be produced.

Then, at the end of the run or batch, the quality results are sent back to the ERP system and become part of the historical record for the order. If required, the certificate of analysis (COA) is generated automatically. Automating these procedures reduces manual efforts and the errors they inevitably produce.

These concepts of seamless information flow can be extended to production order execution. Electronic communication of orders from the ERP system to the production floor, and the status of the production orders back to the ERP system, is an essential practice for any world-class operation.

If you’re currently using paper or white boards to communicate the production schedule or need to have timely and accurate information as to the current status of your orders, ERP integration is the enabler you’ve been looking for.

Lastly, no track-and- trace system is complete without vertical integration between the ERP and the production floor. This is especially important in the food and beverage and life science industries. Electronic integration between the ERP system and the production assets:

  • eliminates error-prone and inefficient paper systems
  • adds a level of granularity to provide greater accuracy
  • reduces recalls, and
  • satisfies regulatory agencies.

Integration between the ERP and operational systems will reduce operating costs, protect your brand and take your business to the next level. MAVERICK has the experience, expertise and project execution capabilities to make this happen in an incremental and evolutionary fashion. MAVERICK is ready to partner with you to define ways to improve your business outcomes. Contact us for a holistic, platform-independent view and analysis, and start getting the gains you need to stay competitive.

Product Manufacturers Optimize CIP Systems

Product Manufacturers Easily Optimize CIP Systems

MAVERICK upgrades CIP systems and provides CIP editing software which allows easy management and optimization of CIP operations.
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Food Manufacturer Plans Expansions

Leading Food Manufacturer Plans Plant Expansions

A leader in authentic and premium food and beverage brands, including extended shelf life (ESL), organic, natural and indulgent favorites, partnered with MAVERICK to baseline current plant operations and develop a plan for upcoming plant expansions.
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Capabilities for an Established Food System

New Capabilities for an Established Food & Beverage System

An international beverage manufacturer needed to add fruit juice processing capabilities to an existing carbonated beverage facility. They required a control system and manufacturing execution system to monitor and supervise this fully automated batch process.
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Producer of Soy Protein Streamlining Business Process

Major Producer of Soy Protein Seeks to Retain Competitive Edge by Streamlining Business Processes and Improving data Availability “from the Plant Floor to the Boardroom.”

A global leader in the manufacturing and marketing of high-quality soy ingredients realized that in order to respond to stiffening competition, its business processes needed the agility to provide the right information to the right people at the right time.
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Manufacturers Utilize Auditing Techniques

Manufacturers Utilize Auditing Techniques to Improve Beverage Packaging Efficiency

Many manufacturers aim to improve operational efficiencies of beverage packaging, generating bottom-line cost savings by reducing equipment outages and material waste and improving system throughput. MAVERICK has helped them achieve these goals through physical equipment assessments, machine downtime audits, production team interviews, root cause analysis, audit team observations and equipment line balancing.
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Chemical Manufacturer Extends Catalyst Life

Major Chemical Manufacturer Improves Ethylene Oxide (EO) Selectivity and Extends Catalyst Life by Implementation of DCS-Resident Advanced Process Controls (APC’s) and Operator Advisory Tools

You’ve got what it takes to meet your goals. Now take your plan to the plant floor with MAVERICK.
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Plastics Manufacturer Increases Production

Major Plastics Manufacturer Increases Production and Reduces Operator Workload Through Advanced Process Control (APC)

A European manufacturer of high-value engineering plastics needed to boost its production rate to meet increased demand for Bisphenol A (BPA), a key intermediate, and the final product, a high-value polycarbonate resin. Although there were no immediate plans to install new equipment, and all other debottlenecking steps had already been performed, the manufacturer had to find a way to maximize its production of BPA.
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Fertilizer Manufacturer Implements Integration Solution

Fertilizer Manufacturer Implements Plant-Wide Systems Integration Solution

A manufacturer of water-soluble fertilizer needed to integrate its plant floor controls with its manufacturing execution system (MES) and enterprise resource planning (ERP) system to improve production monitoring and optimize plant utilization.
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Chemical Manufacturer Reduces Waste Disposal Costs

Major Chemical Manufacturer Reduces Waste Disposal Costs Through Advanced Process Control (APC)

Due to site-wide production rate increases from several process units, the organic waste streams at a chemical plant had grown beyond the combustion capacity of its waste fuels boiler (WFB). Waste that wasn’t burned in the WFB had to be shipped off-site for disposal at a significant (per pound) cost to the business.
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Advanced Process Control Improves Sulfur Content

Hydrotreater Advanced Process Control Improves Control of Product Sulfur Content

Due to frequent changes in the compositions and charge rates of mixed middle-distillate streams, the final product sulfur content of a diesel hydrotreating unit was subject to major upsets, thereby jeopardizing the ability of the refinery to maintain final blended diesel within mandated sulfur specification limits. Control of this most important process variable was a constant challenge for the process operators and was a source of major frustration.
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Petroleum Refinery Converts to Digital System

Major Petroleum Refinery Converts to New Digital Automation System

The client wanted to complete a platform migration as Phase I of a plant-wide modernization project. The client requested a Wonderware human machine interface (HMI) for the newly developed graphics.
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Modernization of Generator Control Systems

Fast-Paced Modernization of Generator Control Systems Meets Increased Power Demand

When Santee Cooper, a leading southeastern utility provider, inherited peaking generator with unreliable control systems, the company launched a modernization project to systems’ reliability and ease of operation. Unfortunately, the company lacked adequate monitoring capabilities and documentation regarding system maintenance.
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Power Plant Owner in Need of Process Control

Industrial Power Plant Owner in Need of Process Control Programming — ASA

An owner of a new power plant uncovered problems with the control system programming. Three months from startup, the plant required immediate assistance to resolve programming and control issues in order to meet operational requirements.
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Automatic Generation Controls in Power Plant

Advanced Automatic Generation Controls (AGC) in Power Plant

An independent power producer needed advanced AGC in order to achieve competitive, market-based, remote dispatch control certification.
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Manufacturer Integrates Vision Inspection System

Manufacturer of Currency Paper Integrates Vision Inspection System to Ensure 100% Consistent Quality

A manufacturer of high-quality paper sought a vision inspection system that would ensure its U.S. currency paper consistently satisfied federal government standards. The speed, accuracy and 100% reliability of this system were essential.
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Manufacturer Improves Accuracy of Testing

Airline Manufacturer Improves Accuracy of Testing with New Touch Probe Certification System

The project goal was to design and build a three-axis test system for recertifying touch probes used in the production and assembly of airplane parts and assemblies. The touch probes are ultra-accurate, ruby-tipped sensors used to verify machining and assembly tolerances on all aircraft to .0001 inch. The yearly recertification of the probes is required to meet current Federal Aviation Administration (FAA) specifications, and the OEMs do not provide secondary testing or recertification services.
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Manufacturer Implements Facility Control System

Semiconductor Manufacturer Implements Facility Monitoring and Control System (FMCS)

The client required the design and installation of an FMCS to provide continuous monitoring and control of the cleanroom environment, utilities plant and support areas for its wafer fabrication facility.
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Manufacturing Facility Requires Fast-Track Construction

Pharmaceutical Manufacturing Facility Requires Fast-Track Construction and Production with 100% FDA Compliance

A manufacturer of high-quality pharmaceutical eyewash solutions needed to establish new systems to ensure consistent satisfaction of Food and Drug Administration (FDA) standards. The speed, accuracy and 100% reliability of these systems are essential.
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Power Plant Upgrades Control System

Power Plant Upgrades Control System

A Fortune 300 company selected MAVERICK to upgrade an existing Modicon 984 PLC control system used to manage the operation of the overall water demineralization process with a state of the art redundant Allen‐Bradley ControlLogix micro‐processor based control system.
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Compound Producer Leverages Wonderware MES

Leading Vinyl Compound Producer Leverages Wonderware MES

MAVERICK partnered with a major vinyl compound manufacturer to develop a manufacturing execution system (MES) based on Wonderware MES which retrieves process order data and returns finished goods, raw material consumption and downtime to the SAP enterprise system.
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Brewery Performs Water Usage Study

Large American Brewery Performs Water Usage Study

A large brewery partnered with MAVERICK to perform a water balance and usage study.
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Data Acquisition System Developed for Solar Cell Stringer

Data Acquisition System Developed for Solar Cell Stringer

MAVERICK was selected by a major supplier of photovoltaic (PV) manufacturing equipment to develop a data acquisition system for their flagship solar cell stringer.
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MAVERICK Develops MES Application with Recipe Management

MAVERICK was selected by a major supplier of PV manufacturing equipment to develop a MES application with integrated recipe management for their modular solar panel production line.
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System Developed for Water Filtration

Product Quality System Developed for Water Filtration Module Production Line

MAVERICK developed a product quality system (SCADA) for a new, flexible water filtration module production line of a major supplier of water filtration solutions.
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Manufacturer Implements MES Upgrades

Water Filter and Purification System Manufacturer Implements MES Upgrades and Enhancements

MAVERICK was tasked with performing a risk analysis and deployment strategy for a system upgrade to the customer’s existing installations of Rockwell’s FactoryTalk ProductionCentre.
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Facility Develops Product Quality System

Steel Plate Heat Treat Facility Develops Product Quality System

MAVERICK partnered with a major steel supplier to develop a system that proves the quality of each plate produced by documenting the product genealogy. In an industry awash with foreign imports, this supplier is able to differentiate its superior offerings from those of inferior producers through the use of this system.
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Heat Recovery Steam Generator (HRSG) Support for Smelter

MAVERICK was contracted to support the startup of HRSGs for the power block on the largest aluminum smelter complex in the Middle East in Abu Dhabi, United Arab Emirates.
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(HRSG) Support for Saudi Arabia

Heat Recovery Steam Generator (HRSG) and Balance of Plant Support for Saudi Arabia

MAVERICK was contracted to support the commissioning and start‐up of a new GE installation in Saudi Arabia for the first Integrated Independent Water and Power Project (IWPP) in Saudi Arabia, producing 2800 MW and 210 MGD of water in Jubail City, Saudi Arabia.
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Leader in Feedstock Builds Second Plant

Leader in Bioproduct Feedstock Builds Second Pilot Plant

A company that develops high quality feedstock for the bioproduct and biofuel supply chain awarded a second contract to MAVERICK to provide engineering and to commission the control, human‐machine interface (HMI) and data historian systems for its second pilot plant.
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Producer Restarts Mothballed Mill

Major Pulp and Paper Producer Restarts Mothballed Mill

A major pulp and paper company partnered with MAVERICK to restart an integrated pulp and paper mill that had been shut down for two years.
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Paper Mill Sets New Benchmark for Migration Project Start‐up

Paper Mill Sets New Benchmark for Migration Project Start‐up

As a key step of the full replacement program of the 1980s vintage DCS and PLC systems, new primary and secondary Rockwell ControlLogix processors for the paper machine were programmed and installed along with new Rockwell drive systems and Emerson DCS.
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