Case Studies

E Technologies Case Study: Pharmaceutical

Implementation of a low-cost Rockwell Automation PlantPAx process automation system brings increased flexibility and better quality for pharmaceutical manufacturer

Project

E Technologies’ Banks Integration Group, a Rockwell Automation Solution Provider, was hired by AMPAC Fine Chemicals (AFC) to upgrade the process control system of a single-product semiwork facility in Ranchero Cordova, California.  During the project, AFC asked Banks to also convert the equipment to a flexible midscale multi-product production facility… with no increase in project budget.

Solution

The existing hard-coded control system was built in the 1990s, and was not capable of handling the flexible manufacturing that AFC desired.  Banks designed and installed an updated process control system that met the strict FDA regulatory requirements and high level of security required for the production of active pharmaceutical ingredients (APIs), and was a cost-effective alternative to a traditional server-based batch solution.

Banks engineers selected the PlantPAx process automation system from Rockwell Automation for the complete control system upgrade.  PlantPAx provided a control solution that allowed the flexibility to easily change the manufacturing schedule and produce more than one product on the equipment.  Additionally, the use of PlantPAx Logix Batch & Sequence Manager allowed a controller-based solution and saved money by removing the need for costly custom code or additional server infrastructure.  FactoryTalk View Site Edition software was chosen so that AFC personnel can configure recipes directly in the controller.

Technology used in the project:

• PlantPAx
• PlantPAx Logix Batch & Sequence Manager
• FactoryTalk View Site Edition
• EtherNet/IP network
• Allen-Bradley FLEX I/O modules
• Allen-Bradley IntelliCENTER motor control center
• Allen-Bradley PowerFlex VFDs

Results

The new control system has improved the quality, consistency and speed of manufacturing AFC’s APIs by automating processes that were once manual.  The new system has reduced reliance on paper-based documentation, which offers additional cost savings.  The success and quick ROI of this project has led to AFC pursuing additional upgrade projects with Banks Integration and Rockwell Automation in other plants.

“With the automated batch solution from Rockwell Automation, we’re improving the quality and consistency of our APIs, and avoiding the delays that naturally occur during manual operations,” said Mike Ryan, director of Automated Systems and Calibration, AFC.  “The Rockwell Automation solution allows us to meet customer needs more quickly than our competitors, while still staying in full compliance with industry regulations.”

Ryan continued, “We need to align ourselves with leading partner companies in order to be competitive and each project we complete with Banks Integration Group and Rockwell Automation is a perfect example of that strategy.”

Download the full case study

E Technologies Case Study: Parcel

Increase of throughput capacity at a global parcel hub

Project

A global parcel service reached out to E Technologies Group after being tasked with increasing

Automated warehouse. Boxes moving on conveyer

throughput capacity in one of their older hubs prior to the peak season for shipping.  The turnkey project involved upgrades to 70% of the site’s control systems, along with expansion of the control room and package handling systems. E Technologies was responsible for the engineering design, software design, procurement of all electrical hardware, electrical installation, start-up, validation, and ongoing support through their peak period.

Challenges

There were several challenges associated with the successful completion of this project, ranging from tightly scheduled downtime, to dealing with delayed equipment deliveries. E Technologies’ engineers closely managed the project and evolved the highly-detailed schedule to accommodate the customer’s needs.  The challenges included:

• The project start date was delayed condensing the original schedule down from 9 months to 5 months
• The scope of work had to be planned sequentially because each upgrade was dependent on the previous one
  

  Box on conveyor roller. Delivery service, distribution warehouse and parcels transportation system. 3d illustration

• The mechanical upgrades had to be completed prior to control system completion, further limiting installation and start-up windows
• All installation and start-up work had to be completed during weekly downtime windows that started Saturday mornings and ended at 11:00 AM on Monday
• Both mechanical and electrical equipment deliveries were “just in time” and sometimes late, requiring a very agile installation and start-up team
• While the customer had very detailed specifications, many exceptions were allowed so that the new installations would match the existing operation.  This required more rigor during definition to review prior precedents set at the hub.

Solution

A dedicated E Technologies project team was deployed to the site to complete definition through both audits and reviews.  The project team produced a highly-detailed report with a list of exceptions to the customer’s specifications.  These exceptions were submitted to the customer for approval prior to the start of the design. The E Technologies team worked with the customer’s mechanical consultants to develop and then continuously refine plans to sequentially install the upgrades in scope blocks that could fit into short downtime windows.  In several instances, multiple E Technologies teams were deployed to the site simultaneously to work in different areas.

The E Technologies engineering design team worked to standardize new electrical panel designs so they could easily be adjusted from one area to another with minimal notice if required.  Software was also standardized to make it more easily supportable during deployment and ongoing.

Once installation began, E Technologies deployed full site management to the hub to oversee all deliveries and installation activities.  E Technologies’ site manager was also the single point of contact for the hub manager and the mechanical consultant, creating a seamless communication channel from the customer to the E Technologies project team.

This turnkey project required rigorous planning and constant communication, making great project management essential.  Since the completion of this project, E Technologies has been awarded several other projects with this customer at the same facility.[Parcel]

E Technologies Case Study: Consumer Products

A large-scale electrical and mechanical safety audit and mitigation project

Project

A global battery supplier reached out to E Technologies Group with their initiative to bring 99 machines into compliance with the most recent electrical and mechanical safety guidelines.  At the start of the project, 79 of the 99 machines had already been assessed and had design bases defining the mitigation scope of work.  The remaining 20 machines still required this work to be completed.   E Technologies was responsible for risk assessments for 20 machines, and implementing the safety mitigation work on all 99 machines.

Challenge

There were several challenges associated with the successful completion of this project, ranging from working around unpredictable downtime, to the sale of the brand mid-project. E Technologies’ engineers remained flexible throughout this multi-year project to accommodate the customer’s needs.  The challenges included:

• After E Technologies’ engineers began the risk assessments, it became apparent that the previously-completed risk assessments were not comprehensive, nor were they accurate. E Technologies held meetings with the client to create and approve new design documents, which all machines were assessed against.
• Because there were many initiatives occurring within the plant simultaneously, the decision makers were rarely focused on the risk assessment logistics.  Flexibility and patience were key in getting customer personnel in place to support the efforts.
• The brand was sold to another corporation, which required some refocusing of priorities, and realignment with the new owner’s practices and procedures.
• The biggest challenge was the project schedule, which required working around production needs that fluctuated based on weather events around the world. Getting windows of downtime for installation was hit-or-miss.

Solution

After writing and approval of the new design documents, E Technologies conducted risk assessments on the machines.  The mitigation plan included installing new mechanical guarding, electrical panels, and E-stop circuits, after which the machines were validated against E Technologies’ written protocols.  Safety maps, Lock-Out-Tag-Out procedures, “One Point Lessons,” and safety training were completed for the customer. Some of the 99 machines were removed from scope due to changes in priorities and capital decisions to replace machines instead of upgrading, and the rest are safe and compliant to OSHA and plant standards.

During this project, E Technologies developed a close working relationship with the customer thanks in part to our excellent communication, flexibility, and work ethic. Since the completion of this project, E Technologies has completed multiple additional projects for safety guarding both at the original plant, and in other locations.[Products]