In our last post, we talked about step one of our progression plan — conducting the Installed Base Evaluation (IBE) as a blueprint for modernization. Conducting an IBE can help manufacturers get a handle on what they have, what they don’t have and what they need in the plant. This was the case for Oreo-brand manufacturer Mondelez International, according to Don Glewwe, project engineer/controls.
Why an IBE?
We knew we had a problem with obsolete devices in the bakery. We assembled a team comprised of the electrical maintenance lead, a business unit manager, and the engineering manager and laid out the situation.
We knew the bakery was at risk but were not exactly sure of the scope of the risk. We needed a comprehensive assessment of all control devices throughout the plant. From that we could develop a plan to mitigate the risks.
One reason companies don’t elect to have an IBE conducted is because of the cost. For us, the IBE was financially weighed against the possible risk, and we decided the IBE was important for Mondelez. The challenge was to come up with a 5-year plan for modernization. We needed the scope of our issues. So the IBE made sense. It was a clear decision for the team.
Mondelez had a lot of older equipment, much of it nearing end of life. Ultimately, we didn’t have a comprehensive picture of our exposure. One such critical item included the Remote I/O for the SLC500.
What was the IBE process like?
More than 300 panels were examined by a vendor representative, including our off-brand items like variable frequency drives. He looked at all the parts in one week. We were amazed at the turnaround time.
There were some real jewels in there as we were breaking down and sorting through it. It helped us to see what areas were at risk. As part of the 5-year plan we decided to choose the more critical areas first using the IBE to determine the scope. The IBE put parameters around the scope as well as a value on it. We had never put it all together in one spot with a dollar value. That was a huge benefit.
With a long range plan, it wasn’t hit or miss. The IBE allowed us to get a look at everything.
What did you find?
It became obvious from the IBE that things on the ovens needed updating.
The IBE was conducted in November 2015. We are implementing the first project on our ovens with the replacement of obsolete controllers. We will replace an obsolete SLC 500 and Remote I/O adapter that is at risk with the ControlLogix system.
Would you recommend an IBE?
It depends on the size of the company. There is no way a maintenance person could walk around and figure this out. It’s very beneficial for larger plants or plants with a lot of turnover in controls.
Mondelēz International is a world leader in biscuits, chocolate, gum, candy and powdered beverages, with billion-dollar brands such as Oreo.