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E Tech Group is seeing a trend across industries as more and more clients are progressing on their digital transformation journey – a transition away from traditional black box solutions to open-source and flexible integrated systems. This is a result of clients wanting more ownership of their systems and the desire for more customizable system data.
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.
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