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DataRealm
is doing the impossible, changing the
controls in a large engine manufacturing
facility while the plant continues to
operate.
For the best part of a year a DataRealm
field team spends its weekends meticulously
swapping out the controls at selected
assembly stations. There is rarely a
hitch in a process that is so seamless
that the plant is able to restart each
Monday for a five day production run
without even a hint of downtime - exactly
as planned and as promised.
One reason the operation is so smooth
is that DataRealm's controls engineers
spend weeks mapping out the plan for
each weekend. One of the unique challenges
they face is that both new and installed
controllers - along with all hardware
and software - must co-exist throughout
the process so that the upgrades will
not disrupt production.
This kind of innovation, which is built
into the DataRealm DNA, will ultimately
save the manufacturer tens of millions
of dollars, avoid discarding still viable
production equipment while upgrading
to newer equipment for a new engine
family and, most importantly, eliminate
the need for a costly and extended production
shutdown.
Most of the programmable logic controls
(PLCs), CNC controllers, HMI and motor
controls in use on the plant floor were
at least three generations behind current
technologies and no longer supported
by their manufacturers. This gap became
so problematic that plant engineers
often searched the Internet to find
replacements for modules well beyond
their best before dates.
DataRealm started the project with a
detailed study to find the best option
and concluded that, when all was considered,
replacing the controls while the plant
continued to operate was not only feasible
but technologically possible. The project
included identifying a PLC controls
vendor with the ability to participate
in such an ongoing program and an installation
company to upgrade some of the plant's
production zones. What clinched the
deal were the multiple benefits of this
unique approach. Despite the downturn
in the North American auto industry,
product demand limited the ability of
the manufacturer to close the plant
for a long and costly retooling.
There was somewhat of a sigh of relief
from the manufacturer when DataRealm
offered its solution. The few concerns
that any number of factors could derail
the effort have been proven to be unfounded.
DataRealm attributes this to its understanding
of the inner workings of a wide range
of control devices along with its years
of expertise in manufacturing IT systems
integration and traceability as well
as the its team's expertise at executing
intricate installs under considerable
time pressure.
When all the stations are complete,
the plant will also enjoy not only a
number of process improvements, including
reducing the number of PLCs in play,
but also a highly modern internal communications
system that will turn once independent
controls into part of an interconnected
highly functional operational network.
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