“Opensoft Systems Ltd were recently chosen to assist us with implementing a numbers enhancements across our plant control systems.
We had a number of engineering days built into our Site Support Contract with Opensoft Systems to use required. Following the work on site, a two-day training session was set up to help with knowledge transfer.
We wanted an adapted / bespoke course to cover not only our SCADA system but our on-site PLC’s at the same time and help us to better understand the interaction between them, a course not readily available anywhere else.
Additionally, our timescales were very tight, we could only spare our own system specialists for two days due to our intense production schedules.
Opensoft developed a two-day training course for us and used our own SCADA and PLC code as the basis for the training for added familiarisation.Training was delivered away from the site at Opensofts Offices and Training Facility in Knaresborough.
Day one covered fault finding and diagnosis of the SCADA system and day two covered the same for the PLC’s and the interaction between them”.
JG: Learned A Lot – Very Valuable – Brilliantly Delivered – Thanks.
MB: Scored the course at 10/10 for Course Content, Tutor and Facilities.”
“Grundon Waste Managment engaged the services of Opensoft Systems after listening to an issue we were experiencing in the Baling area of our MRF (Material Recycling Facility) operations. Our Baler loads recyclable material, where it is compacted to a manageable bale for on processing.
The Baling / Bunker Area on the site is an incredibly noisy area to work in, so mobile phones or 2-way radios for communication with the control room are not a practical option.
Following discussion with Opensoft, they proposed a solution that involved installing a secondary Control Screen in the Bunker / Baler area linked directly to the Control Room Systems via RDP (Remote Desktop Protocol).
This effectively enabled control locally to allow operators to complete their operation on the Baler.
Following which, control was returned to the main control room.
Grundon Site Electrical Engineer said:
The solution was implemented well and serves our needs perfectly.
It enables the operation of the Baler smoothly and safely.
Thanks to all involved. ”
“Opensoft Systems were chosen to implement the new historian owing to their wealth of experience in integrating automation software across fast moving process operations.Opensoft recommended Wonderwares’ data historian, lending itself well to real time process analysis required by the site.
The system linked seamlessly to the sites Kepserver I/O server providing a real time data stream across the plants Mitsubishi Q Series PLCs.
CIP (clean in place) is an important requirement for any food production facility, a change in products manufactured requires a thorough clean of all process equipment prior to re-utilisation for new recipes.Following system implementation, training was provided to assist personnel in understanding the configuration of the historian server’s utilities, management of the system, data analysis and production of reports.
'Meadow Foods’ Group Engineering Manager commented:
"Installing the historian to capture our production data was a key priority for our business.We needed a tool that allowed us to understand after-the-event issues across our plant.Opensoft installed the historian with minimal fuss and aligned the reports to our needs very well.
The historian is an extremely useful tool to understanding plant problems.It allows us to drill down to see what actually caused a particular issue long after it has occurred.Any manufacturer wanting to monitor the efficiency of their production operations should consider having a historian implemented”.”
“Opensoft Systems Ltd was chosen as the contractor to upgrade the existing control system necessary to enable the production facilities automation systems to accommodate a planned upgrade.
Jotun’s Scunthorpe based facility had identified that the site’s current raw materials storage facility required an upgrade. This would enable the site to increase the quantity of raw materials held on site and improve material availability to the plant. The expansion required the sites automation systems to be redeveloped to enable the new larger material tanks to be sequenced effectively into the wider production facility. Jotun’s Site Engineering Manager comments: “Opensoft have worked well to accommodate our tight deadlines on this project and have worked efficiently from start to finish. Due to the criticality of our existing operations on site it was imperative that Opensoft worked closely with our systems team in Norway to ensure a seamless integration of the new tank farm to our Scunthorpe Operations. I would like to thank all involved.”
“Opensoft Systems contacted me a few weeks after our site had experienced a small scale PLC fail. Opensoft's adapted and flexible Siemens S7 training using our own PLC code as the basis for the training seemed to be an ideal fit for our needs and requirements.
A site meeting was arranged and Brian Swatten, Opensoft Client Delivery Manager met with us at our site to review our requirements in greater detail and a personalised and adapted training course was developed to suit our own engineer’s needs and requirements.
Post course feedback from our own engineers was encouraging and we will be working with Opensoft again in the not too distant future.
MC said "this was a good one compared to others”
CC said “previously trained by Siemens but this course was far better””
“We commissioned Opensoft Systems to assist us with making adjustments to our InFeed PLC code to reflect physical movement of several conveyors at our Holme Hall Quarry site near Rotherham.Upon visiting the quarry, Opensoft’s expertise highlighted the necessity to carry out a commenting exercise for our Siemen’s PLC code prior to any changes being made. As part of the commenting process, Opensoft included site visits to our quarry to review the PLC code and how it affects the physical processes within the plant. Code changes were then made to reflect the conveyor moves.Their engineers were very knowledgeable and carried out the whole project in a punctual and professional manner. We used Opensoft as our preferred contractor due to previous experience of utilising their unique AVS software and look forward to working with them going forward.”
“Great training course. Excellent way of learning how to navigate through the software and use many useful functions to increase fault finding ability on plant systems. Dave was very knowledgeable and helpful throughout the week.”
“Fine Lady Bakeries approached Opensoft to deliver a one to one personal training course for myself on our Mitsubishi FX & Q PLC. As I was new to the company I wanted to familiarise myself with our PLCs to be able to diagnose and fault find issues. Opensoft adapted their training course to suit a one to one consultation.The trainer was very professional, implementing a clear set of learning objectives to provide focus and clarity to the lessons. His approach was friendly, informative and very encouraging.
I was very impressed with the course provided and would like to thank everyone who was involved.As a follow up to the one to one consultation, I have arranged a training course for my engineering team to bring them up to a similar standard. We look forward to working with Opensoft again”
“We asked Opensoft Systems to implement their AVS backup and recovery system for our Wonderware SCADA system. The system provides control of our brewing facility and is vital in ensuring our Brewery’s production is maintained.Utilising their AVS software to virtualise our SCADA system provides us with peace of mind that the system and key plant data is kept securely and readily available in the event of hardware failure.
I would highly recommend the AVS product to any production operation as a means of enabling your system hardware to be upgraded and in providing greater resilience to your key production systems.”
“We recently commissioned Opensoft Systems to provide us with greater resilience in our main control system. The system is critical to our site operations and the continuous production of CO2.
They implemented the required engineering modifications across our SCADA and PLC systems swiftly and professionally, the system now provides the added security which we require for our round the clock operations.
Their engineers were punctual, highly knowledgeable and very professional at all times, ensuring a smooth transition.
“We utilised Opensoft to provide a series of maintenance based training courses covering our Rockwell Logix 5000 PLC programme. Our aim was to give our engineers more confidence and expertise when responding to plant faults.The course objectives were clearly defined and the pace of the course was suited to the level of our engineers.The course tutor provided a friendly approach, with a high level of expertise. I would highly recommend Opensoft’s maintenance training modules to other companies seeking to increase their maintenance crews confidence and PLC fault finding expertise”
“We recently called on Opensoft following a failure of a critical PLC operating our UF Filtration Plant resulting in in-operability of our plant.Despite not having a support contract in place with Opensoft, they responded promptly out of hours, to our call, diagnosed the fault and had an engineer to site who promptly fixed the fault. I would highly recommend Opensoft for any future associated control works. Thanks again to all involved in resolving this fault.”
“We utilised Opensoft Systems to provide added technical support and expertise across our Wonderware automation control systems. We have always found their team easy to deal with and responsive to our team's needs for assistance. Their undoubted technical expertise across the Wonderware range of products has provided an added dimension to our team's existing experience. We look forward to continuing to work together.”
“We chose Opensoft's AVS system to provide a much needed upgrade and application resilience to our Line 1 production facility. Our existing InTouch SCADA system had been in situ since 1998 and ran on the Windows NT platform connected to Siemens S5 PLC's.
The hardware the system ran on was naturally becoming a concern to us due to its age and the increasing potential for the SCADA PC hardware to fail.We liked the simplicity at which AVS allowed us to upgrade to the latest Windows operating software whilst retaining our existing InTouch software. The solution also allowed us to remove our legacy serial communications from the SCADA PC's to the plant in favour of Ethernet.
We opted for the AVS server module to provide ongoing data and application backups going forward to what is a critical production facility operating 24 x 7. We are now considering deploying AVS to other areas of our facility. Thank you to all at Opensoft who were involved in our deployment.”
“Opensoft Systems provided us with a manufacturing execution solution to replace our existing process control interface. The solution is fully automated and incorporates full system redundancy and batch reporting across our manufacturing operations. The system is seamlessly integrated into our business IT layer ensuring complete continuity with our production planning tools.Thank you to all for a well managed and integrated project. Detailed, well considered planning and accurate documentation, ensured successful commissioning of the new system without any noticeable disruption to our production operation.”
“Many thanks for the work carried out by your applications engineer, Daniel. He visited our site recently to address a long standing communications issue with our InTouch SCADA system which previous attempts by another integration provider could not resolve.”
“Thank you to your team for providing a swift and prompt response following the hard drive failure of our Syrup 1 SCADA system. From arriving at your premises the day prior with said PC in hand were backup and running the following day. We now intend to implement your AVS solution to avoid this happening in the future.”
“Opensoft successfully implemented a SCADA and Data Historian solution for our gas cylinder heat treatment area.The system has been of great benefit in providing us with reliable data collection and a secure means of backing up our heat treatment furnace profiles.
The system is now a critical business tool for our operation. Thank you to your team for a smooth implementation. ”
“Opensoft provided a system upgrade on a key SCADA system operating our production facility. We needed to maintain the existing functionality of the SCADA system, passing key production data from the process to our SAP server. We involved Opensoft in the initial project design phase with our Production Process and IT team.
The development work was completed swiftly and commissioning of the system went smoothly and against our objectives. We would definitely consider the Opensoft Systems team for any future projects.”
“I recently called on Opensoft Systems to handle a long standing communications problem with our Wonderware SCADA systems, which a previous vendor had failed to address. They diagnosed the issue pretty much over the phone and their engineer implemented their recommendations to a successful conclusion.
We subsequently asked them to undertake a Site Audit of our systems to help identify other areas for improvement that we could make across our site. We now have a support contract in place with Opensoft to provide expertise across.”
“Your AVS software has provided us with the security of regular automated data backup processes and the peace of mind that we have instant recovery of our SCADA application in the event of a SCADA PC failure.
The added benefit of your AVS software, allowing us to effectively upgrade our old SCADA PC's to Windows 7 and new hardware, is a real plus.
Thanks to everyone involved at Opensoft Systems.”
“We employed the services of Opensoft Systems to integrate our InTouch SCADA system to a Citect system, which communicated to a Siemens S7 PLC controlling our evaporator process.
The project was well executed with zero downtime to our production process at commissioning stage.
I would highly recommend Opensoft for any works you are considering.”
“Opensoft Systems have implemented for us a Data Historian, for the secure collection, storage and reporting for our site's operational and environmental reporting requirements. We then asked them to deploy their AVS backup and recovery solution for our main Wonderware, InTouch SCADA nodes.
The system provides us with secure daily data backup and application recovery solution. These systems provide direct communication and data retrical from our plant PLC's, their continued operation is therefore critical to us. It was clear on both projects that their expertise and knowledge was high which gave us the confidence to invest in both solutions. We are considering extending AVS to encompass other systems within our plant. ”
“CSWDC approached Opensoft to deliver a series of Allen-Bradley PLC training courses for our first line electrical maintenance team.We were particularly attracted by their maintenance course, which really did deliver in applying practically, troubleshooting and fault finding training, all skills which my team need to effectively solve PLC faults on plant.
The courses delivered onsite, were adapted to our applications and have provided my team with the confidence they need to get on line and diagnose faults.”
“Opensoft undertook a project for us to integrate our MRP System to our machines SCADA control system. Although not a defined project, we knew clearly what we wanted to achieve. Opensoft understood our needs and explained to us in practical terms how our project objectives were best met, this involved working closely with our Engineering and IT team.
This involved integration to our MRP/SQL system and understanding our production order execution requirements.
Opensoft seamlessly integrated the product order and recipe make up from our MRP system, automatically to our plant SCADA system. Additional control precautions were also put in place to prevent operators producing products to the wrong machine set up. The whole project was executed smoothly and simply in what could have easily been over complicated. I would recommend Opensoft Systems for any similar projects you are considering. Thank you to all involved.”
“We contacted Opensoft Systems to carry out and upgrade our Rockwell, RSView SCADA system, which provides a valuable monitoring function for the control of our furnace operations onsite. Their engineer carried out the work with professionalism and with minimal amount of disruption to our operations. Many thanks to all involved. I would be happy to recommend Opensoft Systems for any further related projects on site.”
“Opensoft have provided a high level of support for our IT control systems across a number of our metal processing & production facilities for the past four years. I particularly like the flexibility their contract offers our business. We have utilised their contract services for downtimes situations, PLC and SCADA modifications and to provide our electrical technicians with maintenance focused training.”
“Our application support contract has provided us with prompt and reliable service across our key manufacturing control systems within the business. We have always found Opensoft personnel to be attentive to our needs, responsive and have always provided us with sound technical advice. We would highly recommend Opensoft's technical and engineering support services.”
“I should like to express my appreciation of the work that your engineers performed for us over the last few weeks in making the switch over to the AVS system such a trouble free experience. Your engineers were also very helpful in other matters relating to virtualisation and software not directly related to the project”
“Opensoft's training was targeted to improve our engineers confidence in getting on line to our PLC’s and being able to diagnose and fault find quickly. This is especially important to us in a downtime situation.Our control systems comprise of Control Logix PLC’s with DeviceNet and ControlNet communications to the plant I/O.
Rather than take three separate training courses, Opensoft integrated our communication types into the standard PLC course to give our engineers an understanding of how the PLC communicates across these networks, a vital component of the training. I would recommend Opensoft Systems training to anyone considering a practical PLC course.”
“The Wonderware InTouch Developer Course we did with Opensoft Systems was very informative and focused on clear objectives. The course was logically sequenced and we felt that we gained valuable knowledge in the fields where we most required training. Our trainer provided an excellent course concept and also provided us with some valuable consultancy for our company after the course was completed. We look forward to working with Opensoft Systems again on future projects.”
“I put in place a series of InTouch training courses to improve the skills and confidence of our engineering technicians. The ability to make application changes and diagnose plant operational issues were our main objective from the training.
Opensoft provided a flexible approach to delivering the training which was related solely to our application on site. This approach really helped my team accelerate their learning.
Thank you to all involved.”