Case Study

Major Building Products Firm Increases Capacity and Yield

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Client Overview

The project included recommissioning and modernizing controls for (2) 300’ long production lines that had been idle for several years. It was necessary to upgrade the 1200 I/O PLC controls from a TI 555 platform to ControlLogix on each line. In addition, the system would require safety enhancements and new servo motion control to increase yield. The project required a single supplier for the system integration and electrical construction services needed to modernize and commission the new system.

Description of Services Provided:

  • System audit and front-end engineering & design
  • Project management and schedule development
  • Design and implementation of safety zone control
  • Design and implementation of Rockwell Automation ControlLogix
  • Implement new control panels
  • Replace hydraulics with electric servo motor control and safety
  • Implement new VFDs with safety
  • Industrial network design using TCP/IP/DLR/Stratix design
  • Integration of new control platform into the Wonderware HMI platform
  • Installation services using RevGen design tools and Status Tracker
  • Start-up commissioning and standby service

Customer Results:

The project achieved operation objectives for increased capacity, improved yield and safety. The implementation and start-up schedule were achieved and the customer’s ROI objectives were realized and exceeded.