A large 40-year-old mid-Western foundry was experiencing significant downtime and prolonged mean time to repair control system elements due to obsolescence and uncoordinated HMI strategy.  They invited Revere to participate in a lean event using Revere subject matter expertise to advise on production risks related to automation.  A major production risk was identified and characterized as a project for the next fiscal year.  Executive management required that the project be accelerated for implementation over an 8-week period in the current fiscal year.


Description of Services Provided:

  • Site assessment and documentation
  • Scope development to replace:
    • 7 control panels
    • 1000 I/O and implement new server-based HMI platform
  • Developed complete engineering package
  • Consolidated multiple SLC processors into a ControlLogix design minimizing controllers
  • Designed and deployed FactoryTalk® View SE server system
  • Built 7 new control panels
  • Implemented new BMS controls
  • Conducted factory acceptance testing
  • Implemented new Ethernet TCP/IP control design


Customer Results:

Revere completed the design and shipped the system to customer site only 8 weeks after the project commenced.  Operations resumed at full capacity after a 2-week holiday outage to install and commission the system.  Production throughout was achieved immediately and after several months of operation, a significant reduction in downtime and MTTR was accomplished.