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The field of networking is undergoing a massive transformation as more artificial intelligence-based tools make their way into products and services. Traditional enterprise networks are immediately poised to benefit and grow as more tasks that used to require costly networking expertise are automated.
A material handling company wanted their network integrated and optimized. Our automation engineers documented and assessed the client’s IT/OT Infrastructure to help identify critical components near obsolescence or end of life.
A large material handling client saw an opportunity for IT/OT convergence, a need to identify vulnerabilities, potential obsolescence, and wanted to push for network optimization. Because we have a good working relationship with this client, we were immediately one of the integrators considered to do the work and the request for a bid was sent over.
E Tech Group, along with another vendor were given the opportunity to perform an initial assessment and based on the results would determine who was awarded this project. If awarded, E Tech Group engineers would be responsible for walking all 32 of their facilities to assess their IT and OT networks while compiling a list of requested data presented in their proposal.
To begin, their IT provided our team documentation around program files for PLCs, HMIs, Drives and we were granted Visios to view network topology. We then requested and were given some network access using different protocols to show where their PLCs, HMIs and Drives were connected on their IT network so they could see deeper into their topology rather than just where their IT switches were.
Once this information was gathered, compiled and returned, it was time to walk the site. We began by utilizing an app that was reworked to help us gather and consolidate the data required for the assessment. Our engineers went panel by panel collecting the requested data and pictures.
From there, it was all entered into the app and allowed us to produce a spreadsheet helping facilitate the build of the first asset database. It then took us a couple of weeks to organize everything into usable data that would allow them to identify the lifecycle of all at risk items that might soon fall into obsolescence and would require optimization or need to be replaced.
Utilizing the report provided by our team, the customer liked the work we had and done and decided to have us alone move forward in walking their remaining facilities to compile the same kind of assessment.
Learn more about IT/OT assessments: the process, the benefits and how E Tech Group can be your partner through it all!
Download our Beginner’s Guide to IT/OT Assessments to gain an understanding of what an IT/OT Assessment is, its benefits, and how to get started today.
A material handling customer had been experiencing motor failures on hydraulic lift tables in their distribution centers. E Tech Group helped their team identify the problem and correct the malfunction with a signal delay timer.
Our partner, Wynright, asked that we get involved to help to pinpoint the exact issue causing $160K a month loss in failed motors and hours of downtime at one of their distribution centers. During the process review with the customer and distribution center associates, it was determined that the failures were likely due to excessive cycling of the on/off state of the motor.
The cycling was a direct result of the hard contact of a foot switch provided to the line associates to raise the lift table. In a normal working position, the associate would stand with one foot on the switch and the normal shift of weight as packages are moved across the worker’s position would cause incidental switching of the motor.
Some instances indicated that in an effort to perfectly position the lift table, the worker would feather start/stop operation, exacerbating the situation. E Tech Group’s extensive experience in material handling automation gave us the perspective necessary to accommodate the human part of the process by altering the machine response.
To remedy this, initially a VFD-based solution was recommended. But we felt a solution with a delay timer that negates the signal from the foot pedal for a short time, stopping the on/off signals would provide a better, more long-term resolution to their issue. Stewart Brinkoeter, our fabrication manager, partnered with our Ohio team to finalize and implement this solution in one facility for a test run.
Just an hour and a half of downtime and less than a third the cost of a new motor, the table was functioning flawlessly and the associate working with the test unit did not discern any loss of functionality. Because of its success, this solution will now be implemented across multiple distribution centers. E Tech Group continues to work with our partners at Wynright to ensure these system updates are performed seamlessly across facilities.
The surge in e-commerce operations and expedited shipping demands have caused unprecedented challenges for distribution centers. To keep the pace, many distribution centers are implementing automation solutions to maximize system throughput and reduce fault recovery time. For a global leader in parcel services, it was mission-critical to develop an extensive fault monitoring and package flow control scheme. The parcel services leader commissioned another company to develop PLC (Programmable Logic Controller) programs for their multiple sortation systems; however, the engineering team was challenged with a tight timeline and limited availability. E Tech Group was engaged to quickly develop and troubleshoot the PLC programs as well as lead the system startup and testing.
To foster seamless parcel routing and pinpoint system abnormalities, their parcel operations required extensive fault monitoring and suppression for Human Machine Interface (HMI) animation and fault logging, conveyor operation, as well as package flow rate tracking. One aspect of maximizing throughput required the monitoring of package flow to adjust the feed rates for optimal input supply without exceeding the max system capacity. Maintaining throughput also relates to fault recovery times. “Proper fault suppression is a result of monitoring the status of every circuit breaker, Ethernet adapter, VFD status, power supply status, and all IO cards in the local and field racks.” explains Vimal Sandhu, E Tech Group Senior Controls Engineer about the importance of a fault isolation system. “For example, if a particular circuit breaker tripped, the loss of power may cause the PLC(s) to lose communications with numerous field devices. This can result in anywhere from 1 to 100+ unique faults displayed on the HMI. With proper fault suppression logic in the PLC, only the circuit breaker fault will be displayed. With fault suppression, troubleshooting time is greatly reduced which not only helps maintenance, but also aids in reducing system downtime.”
Experienced in PLC program development with sortation and conveyor machinery, E Tech Group prioritized the commission of the primary sorter systems which included diagnosing and correcting errors in the newly developed logic followed by extensive testing. Once completed, the team promptly set up the communication between the PLC and the customer’s warehouse management system. E Tech Group then proceeded with the setup of the numerous conveyor belts that were required to run with the package tracking logic.
With changes satisfactorily completed to the primary sorter systems, E Tech Group was able to direct the former lead engineering team to update the subsequent systems. E Tech Group stayed onboard to support further testing as well as commission the remaining parts of the primary sorter line. Within a few months, the system became fully operational with E Tech Group’s programming support. The parcel services leader was able to fully maximize its large scale distribution center operations, and E Tech Group was later invited to lead the development, startup, and testing of the second phase which included an additional five sortation systems.
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