Autotronix engineers a PLC and HMI based Andon system for plant production

November 2016 System Integration & Control Systems Design

A component supplier to a leading automotive manufacturer recently experienced a problem at its plant, whereby it could not reflect the planned production requirements versus actual production to management and operators. It could also not produce data on the plant’s downtime. Additionally, there was no method of calling for a maintenance crew, a team leader or the quality control department.

The Autotronix solution

Autotronix was asked to provide a solution to overcome this dilemma. After discussing requirements with the client, Autotronix proposed a solution using a Mitsubishi PLC to read in the production data from field equipment plus a touchscreen HMI for supervisors to type in relevant production information and shift times.

The Adroit scada – interfaced with the PLC – was used to reflect status information such as the planned number of units to be made of a particular part, the actual quantity of that part made, which parts are running on the line at that moment, the list of parts to be made next, and the list of parts completed.

It also indicates the downtime experienced by the plant and displays which, if any, department is being called by the operator; all on a large 65” monitor installed high on the production floor to enable all staff to view the data.

Project scope

This project involved the installation of a PLC, control panel, wiring to limit switches and sensors for the monitoring of production data, installation of a scada system and the remote display of these parameters on the production floor.

The PLC was programmed to initiate a siren when it is time for a break, when the machine is stopped or when a department is summoned. It automatically changes the melody of the siren to different melodies in order to indicate the type of message.

Results

The production manager was impressed with the system as it exceeded expectations in terms of the operation, as well as the turnaround time to develop, install and commission the equipment.

Training was provided to the production manager, team leader, and staff at maintenance and operator levels. A complete backup of the system was also handed over, along with operating manuals and drawings of the system.

For more information contact Collin Chetty, Autotronix, +27 (0)31 705 0400, [email protected], www.autotronix.co.za

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