Autotronix engineers a PLC and HMI based Andon system for plant production
November 2016
System Integration & Control Systems Design
Compiled by Jithen Mathura.
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
Further reading:
Containerised Electrical & Control System Powers Paste Plant in Botswana
System Integration & Control Systems Design
Delivering a complete, containerized solution for a mine’s paste plant in Botswana, this project stands as a model of modern EC&I execution — integrating electrical, control, and automation systems into
...
Read more...
Control system upgrade: Smelting
SAM Systems Automation & Management
System Integration & Control Systems Design
Systems Automation & Management recently completed a major control system upgrade in the smelting industry. The project was delivered on budget and achieved a positive ROI for the client.
Read more...
Gottwald drives upgrade: Ports and harbours
Abacus Automation
System Integration & Control Systems Design
In the ports and harbours sector, Abacus Automation completed a significant modernisation of a Gottwald crane, improving both operational reliability and serviceability.
Read more...
Mining industry upgrade: From ageing systems to maximum capacity
System Integration & Control Systems Design
Iritron recently undertook a major upgrade in the mining sector, focusing on washing and screening plants, jigs, thickeners, tailings, water systems, conveyors and reclaimers.
Read more...
Agogo Integrated West Hub Project: FPSO/subsea offshore Angola
Moore Process Controls
System Integration & Control Systems Design
The Agogo Integrated West Hub project represents a historic milestone in the FPSO and subsea industry, achieving first oil offshore of Angola. This project is the first FPSO deployment since ANPG’s establishment in 2019, and the first major project for Azule Energy since 2022.
Read more...
Integrated Robotics and Control Systems Deliver 45% Production Boost at Aquazania Waters Project and Industry
Process Dynamics
System Integration & Control Systems Design
Project and Industry Process Dynamics designed and commissioned a state-of-the-art Reverse Osmosis
(RO) water purification and automated bottle filling plant for Aquazania Waters in Linbro Park, Johannesburg.
...
Read more...
Digital transformation from the edge
DirectLogic Automation
System Integration & Control Systems Design
Edge-enabled PLCs are an accessible and affordable way for most users to collect and create value from use field-sourced data.
Read more...
Powering southern Africa’s industrial evolution for over five decades
Oilpower
System Integration & Control Systems Design
Established in 1974, Oilpower is a recognised name in South Africa’s hydraulic and pneumatic sector. What started as a small, family-run business has matured into a highly structured operation with specialised teams, experienced engineers and a reputation for technical excellence and reliability. Oilpower is celebrating its 50th anniversary this year
Read more...
Metal plant automation upgrade
ABB South Africa
System Integration & Control Systems Design
A combined compressor house (CCH) control system replacement project, undertaken by NJC, an ABB Authorised Value Provider (AVP), has won high praise from client ArcelorMittal.
Read more...
SIs - the channel’s conductors of light
Schneider Electric South Africa
System Integration & Control Systems Design
Today’s original equipment manufacturers are innovators in the truest sense, driving the absolute newest in technological advancement. While they develop advanced and often groundbreaking solutions, it is the system integrators who bring these innovations to life.
Read more...
printer friendly version