SCADA System, Food Manufacturer

Cygnus successfully implemented a new SCADA system to support our client’s Continuous Process Improvement initiatives at their production facilities. The need was for more effective monitoring and control of real-time production metrics, machine downtime, process alarms and quality test results.

The solution we implemented was designed to:

• Collect real-time production and quality information from plant equipment;
• Calculate real-time production efficiency metrics;
• Display the metrics to plant staff using several large, wall-mounted screens; and
• Provide management with visibility to all plants.

The successful completion of this project provided important support to the client’s Continuous Process Improvement initiatives, allowing the company to achieve, manage and track significant improvements in efficiency, quality and waste reduction.

Power Control SCADA System,
Public Transit Operator

Cygnus was contracted by one of the largest public transit operators in North America to implement a power control SCADA system using Wonderware (now AVEVA) System Platform. The project included engineering design, cyber security plans, secure network design, and configuration of the new SCADA hardware and software.

The system is required to operate on a continuous basis 24 hours a day and 7 days a week, as it supports both operations and maintenance activities including monitoring of security and fire alarms. It provides broad-based monitoring and control of fixed facilities including 80 passenger stations and 62 traction power substations. Key functions include control and monitoring of subway traction power control, monitoring and management of surface (streetcar) energization, emergency ventilation monitoring, information storage and retrieval and integration with the train control and signaling system.

Services provided by Cygnus include engineering design, cyber security planning, secure network design, migration of over 250 screens and integration with both modern and legacy PLC and RTU hardware during multi-phase commissioning. To meet a specific client need, Cygnus developed an OPC server to connect the new system to the legacy RTU hardware. High client satisfaction ratings were maintained throughout the project, leading to successful commissioning and start-up.

CygnusMES Implementation and Integration, Consumer Packaging Manufacturer

Cygnus was engaged to complete an initial review of existing systems for the Canadian division of the largest supplier of molded fiber egg packaging companies in the world. This review included an evaluation of ERP, MES and SCADA integration.

To address identified gaps and to better align systems with business needs, Cygnus implemented a Manufacturing Information System which was fully integrated with existing ERP and plant automation systems. This was done using Cygnus’ proprietary MES software (CygnusMES™) and included production order dispatching and tracking, automated downtime registration, performance metrics (OEE), shift order management & reporting and production/KPI reporting.

The project was implemented seamlessly, with no disruptions to the operation. As a result of the capabilities of the system, the client was able to achieve steady productivity gains which led the company to improved profitability and eventual expansion. When a new plant was built, the same CygnusMES™ system was installed.

The CygnusMES™ has become a mission-critical application, relied on by Operators, Supervisors, Maintenance, Production Planners, Management, and Supply Chain planners to effectively execute their functions.

Equipment Condition and Performance Monitoring, Nuclear Generating Station

Cygnus provided senior technical and project management support to an implementation of an equipment condition monitoring system for a major nuclear power generation station. Cygnus’ role included the design of the high availability SCADA architecture.

Working with the client’s Design Engineering group, Cygnus successfully achieved the client’s stringent requirements for formal engineering documentation, development, risk management, cyber security, testing and verification processes. The result was a solution that provided important Security, Equipment Reliability and information benefits to the operation.

The project delivered a SCADA data collection and monitoring backbone, fully integrated with existing automation systems and implemented using vendor-supplied integration products and Wonderware (now AVEVA) SCADA software.

The system includes approximately 50,000 I/O spread over multiple operating units (reactor and turbine/generators). The system is fully redundant with multiple application servers and archive servers. Interfaces were developed to integrate seamlessly with legacy control systems. In addition, the system provides functionality to transfer process data towards a corporate long-term archive system.