E Technologies Case Study: Metals
Cold mill improvements yield measurable financial savings for leading steel industry customer
Project
E Technologies’ Glenmount Global group was hired for a large project by a leading steel company to increase throughput and safety on the customer’s six stand cold mill line. Additional project goals were to reduce head and tail off gage, reduce inner stand strip breaks, reduce electrical downtime, and improve safety.
Solution
E Technologies (Glenmount) conducted a mill drafting study to determine HP and speed limitations, reviewed the mill model, and set up proper procedures. E Technologies conducted an equipment audit to determine the failure rate and root causes, and then began implementing the audit’s recommendations. E Technologies implemented monitoring and tuning of the inner stand tension, MG set stand one custom 12 pulse drive to fit on existing gen base, screw down clutchless control, and regulated the voltage to the speed reg. Additionally, a safety study was performed and the recommendations implemented, and installation, startup and commissioning were performed.
Results
This successful project reduced head and tail off gage, reduced strip breaks, WR and BU roll wraps by 50%, improved strip shape, increased annual tonnage, and reduced electrical downtime by 50%, resulting in a quick ROI for the customer.
E Technologies Case Study: Metals
Expansion of line capabilities and upgrade to state-of-the-art Siemens digital drive system returns roll coater paint line to maximum profitability
Project
E Technologies was hired for a large project by a leading steel company to expand their line’s capabilities to begin production of light gage steel, and increase throughput on existing operations by upgrading an existing roll coater paint line to return it to the OEM specs of 1600 fpm.
Solution
To accomplish this, E Technologies conducted an equipment audit and determined the failure rate and root causes, and conducted a tension study to determine the equipment’s limitations. This data was then used to improve the tension control on the line by monitoring tower operations and load cell closed loop tension regulators, then tuning them accordingly. E Technologies also analyzed cable conduit versus using remote I/O, performed a safety study and implemented the study’s recommendations, and performed startup and commissioning services of the plant.
Results
This successful project installed a state-of-the-art Siemens digital drive system with new PLC, operator stations, and HMI. The result was a 33% increase in line speed; the line was returned to the maximum OEM-spec speed of 1600 fpm from 1200 fpm prior to the upgrade. Another result of the upgrade was a 50% reduction in electrical downtime. With the hardware and software installation complete, E Technologies expanded the line’s capabilities to include the production of light gage steel.
E Technologies Case Study: Pharmaceutical
Implementation of a nearly $2M process control system in a pharmaceutical manufacturing plant, including a manufacturing execution system for FDA-compliant data collection and reporting, a building management system, and other vendor-supplied control systems
Project
E Technologies implemented a $1.8M process control system (PCS) for the Massachusetts Biologic Laboratories (MBL) state-of-the-art facility in Mattapan, MA. The MBL facility performs cell culture and purification of monoclonal antibodies (MAb) and filling of licensed and R&D stage liquid parenteral (injectable) products that cannot be terminally sterilized. The monoclonal antibody production centers around cell culture and purification.
Solution
E Technologies installed a PLC- and SCADA-based PCS system utilizing redundant Allen-Bradley ControlLogix 5550 processors with 1756 series I/O, 1794 Flex Series I/O, Festo solenoid blocks, and Mettler Toledo scale indicators. The I/O is distributed between 13 control panels which are interconnected with DeviceNet and ControlNet I/O networks. The PCS communicates approximately 400 data points over Ethernet to the various equipment vendor-supplied systems.
The PCS consists of a SCADA/Historian fault-tolerant server, manufacturing execution system (MES) fault tolerant server, web reporting server, 11 portable client workstations, 7 fixed client workstations, and 2 engineering workstations. The 11 portable workstations contain wireless Ethernet capability and are mounted on a portable cart with an onboard battery and barcode scanner.
The following software packages were used as part of the PCS system:
- SCADA – GE/Proficy iFix
- Historian – GE/Proficy Historian
- Data Analysis – GE/Proficy Real Time Information Portal
- Reporting – Crystal Reports
- Manufacturing Execution System – Elan XFP, Oracle database
- Alarm/Event Storage – SQL Server
The following equipment is located in the MAb production area:
- Buffer preparation tank
- Portable pH adjustment tank
- 55L, 500L, and 2500L bioreactors
- Portable Q-eluate tank
- Harvest tank
- Portable nanofiltration tank
- Chromatography skid
- Final bulk tank
- Ultrafiltration / diafiltration skid
- Fill / finish production
- Vial washer, parts washer, and autoclave
- Depyrogenation tunnel and filling line
- Labeling and packaging equipment
The following utility systems are located in the MPL Mattapan Facility:
- Water for injection (WFI) pre-treatment / soft water generation
- Acid day tank
- WFI still, and hot WFI storage tank
- Caustic day tank
- Compressed air generation
- Clean in place (CIP) skid
- Chilled process glycol generation
- Clean steam generation
- Hot process glycol generation and distribution
Results
Superior Controls implemented a PCS to control process and cleaning steps for the buffer preparation tank, harvest tank, pH adjustment tank, Q-eluate tank, and nanofiltration tank through hardwired I/O. The PCS coordinates CIP operations with the CIP skid, controls CIP and WFI distribution, and interfaces with the various equipment vendor-supplied systems over Ethernet. The PCS stores alarms and process data from the skids and hardwired I/O.
The PCS provides a MES that includes material tracking, equipment management, barcode recognition and creation, and electronic work instructions (EWI) for execution of process steps in the MBL facility. Operators use barcode scanners to verify and record raw materials, semi-finished goods, finished goods, and equipment that is created and/or used in the MBL facility.
The system also consists of a number of equipment vendor-supplied control systems and a building management system (BMS). The PCS provides supervisory control and data acquisition (SCADA), batch execution, electronic work instructions, material tracking, equipment management, barcode recognition and creation, historical data collection, and reporting. All data collection is in accordance with 21 CFR Part 11.
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.”
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.”
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]
