+7 (495) 777 2626
Ask a Question

Industrial automation

Automated process control system

Process Control Systems (PCS) is a group of automated tools to manage the industrial and technological processes in industrial plants without direct human intervention.

Completed projects More

Automated process control system

Process Control Systems

Process Control Systems are designed to minimize or altogether avoid manual interventions into industrial process management. PCS core functions are:

▪     To collect and process various parameters obtained from field-level basic receivers and sensors

▪     To control the condition of technical equipment

▪     To directly manage a manufacturing process

▪     To provide an HMI-based visualization of the manufacturing process

▪     To keep an archive of manufacturing process parameters available at various levels of detalization

▪     To keep a report library

▪     To provide integration with MES-class manufacturing process management systems

PCS reduces accident risk, ensures tighter control over product quality, helps optimizing capacity utilization.

VERYSELL Group designs and deploys a wide range of PCS solutions tailored to needs of various industries from mining and metallurgy to machine building, energy, chemistry and petrochemistry.

PCS Reduce Industrial Disaster Risks

Our PCS are built around a 3-level architecture:

  1. The field level includes receivers, sensors and additional devices, distributed input/output points, frequency inverters, etc.
  2. The second level is represented by management systems based on programmable logic controllers.
  3. The top level is the point of coordination, process optimization, feasibility analysis, manufacturing process data archiving involving server devices, automated workstations and engineering workstations.

Our solutions run on equipment from top manufacturers like Siemens, Schneider Electric, ABB, Emerson, Honeywell, Yokogawa, etc.

Completed projects Быстрый запрос

Supervisory control automated systems

Without the use of IT is impossible to dispatch control at many industrial enterprises, transport, social and communal services.

Completed projects More

Supervisory control automated systems

Now a solid IT element is an integral part of operations control centers at modern industrial plants, transportation companies, utility and social care facilities. To maintain their their ongoing activities, Supervisory Control Automated Systems are applied. Collecting initial data from controllers, receivers, CCTV monitoring systems, field staff or from external systems, these systems inform supervisors via friendly administration GUIs. In other words, Supervisory Control Automated Systems establish contact between people and Process Control Systems.

Taking into account the above, key functions of the SCAS are the following:

▪       Visualizing and arranging miscellaneous data on industrial processes

▪       Tracking compliance with manufacturing standards

▪       Providing fast response to emergencies

▪       Monitoring the quality of supplies, unfinished and/or finished goods

 

Implementation Advantages Reduce the System Pay-off Period to 1.5 - 3 years

Systems by VERYSELL Group are based on hardware and software tools from leading manufacturers and vendors like Schneider Electric, Siemens, ABB, Emerson, Honeywell, Wonderware Invensys. Leveraging benefits of tried and trusted methods, we customize and adapt them to each specific case.

Completed projects Быстрый запрос

Manufacturing execution systems (MES)

Manufacturing Execution Systems (MES class systems) in industrial enterprises operate brain role in the management of production and technological processes.

Completed projects More

Manufacturing execution systems (MES)

MESA (Manufacturing Enterprise Solutions Association) defines MES as a dynamic information system ensuring efficient manufacturing activities. Using accurate and relevant data, a MES initiates operations, controls them and makes required records corresponding to actual events.

It is obvious that an adequate implementation and application of a MES system yield a considerable competitive edge to businesses.

Also note that information on technological and manufacturing processes is supplied in real time from all sites covered by the system ensuring continuous monitoring of performance against plans, as well as coordination of activities of departments and staff.

Moreover, statistics built by a MES allow optimizing manufacturing processes, downsizing manufacturing cycles and keeping the quality up.

Official statistics read that on average MES implementation can:

▪       reduce a manufacturing cycle by 45%

▪       accelerate data collection and processing by 75% or more

▪       reduce the unfinished goods stock by 24%

▪       reduce paper reporting by about 61%

▪       shrink redundant document flow by 56%

▪       accelerate new product assimilation by 27%

▪       provide an 18% reduction in factory rejects volume

The highest synergetic effect is achieved when MES are integrated with ERP, SCM and other enterprise-level systems. Then, aware of the current state of operations 24/7, the leadership can better plan capacity utilization, accurately estimate the need for raw materials and supplies ahead of changes in the product range or nature, manage risks related to non-execution of obligations towards customers or distributors.

VERYSELL’s team has successfully completed a whole range of projects involving MES implementation at metallurgy and mining plants in Russia and around the CIS. Our solutions rely on software platforms from leading vendors, in particular, from Schneider Invensys Wonderware, Simatic IT, PSI, GBO Datacomp etc.

Completed projects Быстрый запрос

Enterprise manufacturing intelligence systems (EMI)

EMI class systems (Enterprise Manufacturing Intelligence) designed to collect and process the analysis of the progress of production data.

Completed projects More

Enterprise manufacturing intelligence systems (EMI)

EMI (Enterprise Manufacturing Intelligence) is an abbreviation covering a whole class of systems handling collection, processing and analysis of data on the status of manufacturing process. Unlike more common ERP-systems designed to record mid-term results (e.g.: week, month, quarter, etc.), an EMI provides real-time data and represents the top level in the hierarchy of automated systems supporting manufacturing: Plant Control System–> Supervisory Control Systems–> MES –> EMI.

EMI systems underlie solutions designed to support decisioning and to increase management efficiency.

Analyzing data supplied by an EMI system, company or plant executives can evaluate the current situation at any given moment, and optimization opportunities, work out a business development strategy taking into account all nuances, as well as get a clear view of results of measures taken by drilling down to their effect on separate operations.

EMI = 5 to10% increase to net profits

 

VERYSELL deploys EMI systems based on platforms of various vendors. Each is a versatile ready-made solution designed to integrate industrial applications with business systems.

Completed projects Быстрый запрос

Laboratory information management systems

LIMS are widely applied in a whole range of industries, in particular, in oil and gas processing, petrochemistry, chemistry, metallurgy, pharmaceuticals and food manufacturing.

Completed projects More

Laboratory information management systems

LIMS are widely applied in a whole range of industries, in particular, in oil and gas processing, petrochemistry, chemistry, metallurgy, pharmaceuticals and food manufacturing. LIMS are designed to sustain product quality at a competitive level and to ensure compliance. A modern LIMS manages laboratory activities, ensures relevant record-keeping, sampling at various stages of manufacturing process, registration of required specifications, result logging.

It is noteworthy that, apart from monitoring quality of finished goods, a LIMS can control work-in-progress, raw materials and supplies.

LIMS means sustainable quality and better performance

VERYSELL Group designs and deploys comprehensive LIMS that manage laboratory operations at all stages and areas: activity planning, sampling and analysis, task distribution between departments and employees, equipment control, result logging and subsequent estimates based on them, result matching against applicable standards and requirements.

Completed projects Быстрый запрос

Equipment condition monitoring systems

Continuous automated monitoring of machinery condition reduces risk of failures, accidents and emergencies at manufacturing facilities, ensures timely detection of abnormal behavior or faults.

Completed projects More

Equipment condition monitoring systems

Continuous automated monitoring of machinery condition reduces risk of failures, accidents and emergencies at manufacturing facilities, ensures timely detection of abnormal behavior or faults. To handle these tasks, VERYSELL Group offers solutions built around a multi-parameter expert system that analyzes equipment condition and tracks its dynamics.

Core functions:

  • Simulation of probable fault scenarios on the basis of statistics
  • Integration of big data on technical equipment condition into a single database
  • Data exchange with a local ERP-system, maintenance and repairs system

Apart from optimizing maintenance and repair costs, implementation of an Equipment Condition Monitoring System yields a 30-40% reduction in the number of emergency repairs.

Completed projects Быстрый запрос

Mobile staff management systems

Major industrial facilities with geographically distributed structures face a serious challenge when it comes to efficiently managing mobile service teams.

Completed projects More

Mobile staff management systems

Major industrial facilities with geographically distributed structures face a serious challenge when it comes to efficiently managing mobile service teams. Adequate automation of this function simplifies planning repairs and maintenance tasks, as well as the related coordination by supervisors. Moreover, a real-time request processing option ensures fastest response to a machine malfunction, vehicle failure, etc., this reducing emergency costs of manufacturers.

Mobile staff management systems facilitate scheduling of repairs, load distribution between the staff, task progress monitoring and reporting.

Implementation of a Mobile Staff Management System improves team performance by 20-30%

In other words, automation at this point drives up efficiency of the relevant function alongside reducing overall operational costs and minimizing negative effects of emergencies.

VERYSELL Group offers solutions from several vendors, including leading systems by ABB Service Suite.

Completed projects Быстрый запрос

Operations centers

A modern operations center aggregates data from multiple feeds and represents an indispensable element in the management structure of a large-scale manufacturing facility.

Completed projects More

Operations centers

A modern operations center aggregates data from multiple feeds and represents an indispensable element in the management structure of a large-scale manufacturing facility.

Core functions:

  • Controlling operations around the whole geographically distributed facility
  • Providing updates on current situation at each site
  • Monitoring performance against plans and programs
  • Helping to predict probability of failures and emergencies; relevant scenario simulation

VERYSELL Group designs and implements operations centers as comprehensive software and hardware suites embracing a set of models allowing users to:

  • collect initial data from various feeds
  • process the retrieved information
  • provide results in an analysis-friendly format

Thanks to fast operation, our systems provide 24/7 access to the latest information on actual situation at the facility ensuring timely and efficient response to emergencies.

Completed projects Быстрый запрос

Information security of automated process control systems

VERYSELL develops and deploys comprehensive information security systems. Also, to protect PCS of industrial facilities we offer solutions based on Shield platform.

Completed projects More

Information security of automated process control systems

Now almost any enterprise faces information security risks.Obviously, viruses, stealing of sensitive data or planned attacks against systems managing critical manufacturing modules are fraught with most serious consequences. To prevent these, VERYSELL develops and deploys comprehensive information security systems. Also, to protect PCS of industrial facilities we offer solutions based on Shield platform.

Critical Risks Account for 65% of all PCS Vulnerabilities!

These tools ensure unbiased assessment of overall system security and of its separate units, applications, elements.

MaxPatrol relies on comprehensive penetration test tools (Pentest), system audit and compliance instruments. Also, it performs analysis of various operating systems, DBMS and web-applications ensuring ongoing technical audit of security at all levels of an information system.

MaxPatrol supports key Russian and international standards: GOST ISO/IEC 17799, GOST ISO/IEC 27001, SOX, PCI DSS, NSA, NIST, CIS, where GOST stands for abbreviation of the Russian National Standard System dating back to the USSR.

Completed projects Быстрый запрос