E Tech Group’s system integration expertise resolved complex integration challenges for a major food distributor, fostering trust and future collaborations with the customer.
Challenge
Challenges in complex projects are inevitable, but the dedication to overcome challenges is what sets exceptional system integration firms apart. This case study highlights how E Tech Group, stepped in when another company was unable to fully execute a project. The case study underscores how E Tech Group’s exceptional capabilities not only remedied the situation but also earned the trust of the client to support three additional projects to-date.
The client, a major food distributor, needed to integrate a conveyor system with their pocket filler, vacuum filler, and steamer. Delays in the system deployment resulted from understaffed control support, incomplete project aspects, and equipment transfers from another facility. Plus, new conveyors had been installed by a different controls integrator. The client sought E Tech Group’s help to create a clear project outline and overcome the project challenges.
Solution
E Tech Group staffed the project with highly skilled engineers with expertise in canning lines and control strategy. First, the project team examined the state of the production line to determine what needed to be finished. They discovered that the current contractors involved were facing too many challenges with the conveyors before the system could become operational and the project deployment lacked direction because of this.
E Tech Group’s engineers presented a 30 itemed punch list to the startup team which became the central punch list for the project. E Tech Group met with plant technicians to determine how the existing OEM equipment interlocks to the conveyor system and met with OEM experts to have a firm understanding of the pocket filler design. The conveyor company later left the site without completing their controls, which caused E Tech Group to create a controls strategy that integrated the conveyor system with the existing pocket filer, vacuum filler, and seamer. The project team corrected electrical issues, standardized the programming between each OEM equipment and conveyor system, and tested the system’s functionality including the customer’s existing Allen Bradley ControlLogix PLCs and PanelView Plus HMIs.
Results
By promptly tackling issues and implementing effective solutions, E Tech Group restored the project’s trajectory within weeks. The team’s expertise not only conquered challenges but also built client trust, leading the customer to engage E Tech Group for three additional projects to-date. E Tech Group rose to the occasion with system integration expertise and dedication, helping the client reach their goals and supporting positive project outcomes.
Pig Iron Caster Project Pours Hot Metal Ahead of Schedule
E Tech Group’s role shifted to that of a Main Automation Partner for a metals project with an ever-evolving scope of work. Our team effectively managed risks and delays, communicated changes promptly, and maintained a strict timeline, which ultimately enabled the client to complete the metal pouring process ahead of schedule.
The Project: Expand a Production Line to Meet Increased Steel Demand
A metal processing facility was developing a project to install a Pig Iron Caster with the goal of producing half a million tons of pig iron per year to meet rising demand and prices. They would be utilizing the existing blast furnace to feed this new installation, but would need to source the Pig Iron Caster, Bag House components and other heavy machinery, while simultaneously sourcing all required permits.
Once received and installed, the equipment would need to have all of the process control systems integrated and centralized through the control of an integrated HMI. This is where E Tech Group was called upon to function as what they had originally termed an “Umbrella Integrator”, helping bring all these disparate systems together and create a seamless user experience for field operators.
However, as with many control system expansions and upgrades, it quickly evolved into much more.
The Challenge: Overcome Supply Chain Delays & a Fast-Tracked Timeline
At a time when supply chain issues plagued most if not all industries, getting a single piece of machinery to install, test and move to the next as they would in front-end loading (FEL) wasn’t practical to maintain the identified timeline. So they pivoted to a fast-track approach.
Fast-tracking the automation system expansion meant we had less time to review and less engineering documentation available, as the pig caster and baghouse needed to be ordered in parallel. This approach, as opposed to the traditional, rigorous review process that preceded the ordering of any large equipment, meant ensuring minimal alterations during installation would pose a challenge, to say the least.
In order to best navigate the intersection of supply chain woes and a ticking clock, as construction began, it did so with limited and early design while detail engineering was still being drafted. This meant that extra care had to be taken with the early design to avoid any major disruption.
Due to the nature of the project, the schedule unavoidably continued to undergo incremental changes as potential challenges were identified… keeping all stakeholders up to date, open and constant communication was necessary to mitigate any delays. Thankfully, this type of communication is something E Tech Group brings to every automation project we undertake, so even in a constrained timeline and long waits on equipment, we were in our wheelhouse.
Changing Roles: From Umbrella Integrator to Hybrid Project Manager & Main Automation Partner
While E Tech Group was originally contracted to work within the role of an “Umbrella Integrator”, perpetually evolving project conditions would dictate that the team worked in a flexible role that transformed into more of a Hybrid Project Manager and Main Automation Partner.
Very early on, the client determined that the original plan for the critical ladle tilting component, controlling the pour rate of molten steel, would not work in its manual configuration. Our team worked quickly to create an automated solution for this piece that would allow it to function as required.
Recognizing E Tech Group’s ability to lead and problem solve, the team was asked to work in the interest of the client to not only complete what we were originally contracted but move the project forward to the finish.
The Solution: (Always) Go Above & Beyond for the Client
Control panel design should always be informed by the to-be operators; it ensures the client is able to take full advantage the advanced automation solution implemented by our team. Our automation engineers worked with all of the field operators to better understand their wants and needs. This helped develop the scope necessary in the creation and integration of the control solution they would all be using, ensuring it felt like one cohesive system.
Using the defined scope, the on-site team took points, evaluated and worked with the individual vendors. They then reviewed the vendor’s individual prints, programs and HMIs. The team also helped facilitate factory and site acceptance testing and provided onsite resources for other vendors for dry testing.
All of this fell outside of our original scope of work, but allowed the team to continue building trust with the client and functioning as a main automation partner for the length of this project.
The Result: Open Communication & Client Partnership Drove Success
Due to the nature of this project, the escalated timeline, supply chain issues, and shorter-than-normal lead time for engineering design, there were a number of changes that needed to be made. Our team was not only effective in quickly adapting in moving this project to the finish line but also in communicating changes in the timeline that would impact deliverables.
The client was truly appreciative of how the team and E Tech Group as a whole worked with them in helping make the best decision in the interest of the project while simultaneously executing and helping get them operational.
Pouring Metal Ahead of Schedule!
Because the team actively mitigated risk and delays, quickly communicated changes, and worked steadily to maintain this very escalated timeline, the client was able to pour metal almost a quarter ahead of schedule.
Our team truly performed outside their traditional scope of work, above expectation, and was there for the client from beginning to end. This is why they were asked to stay onsite and continue to help identify potential risks and opportunities. E Tech Group continues to mitigate unforeseen risks and help capitalize on opportunities that have yet to be unlocked in their machinery.
Overhauling a Botched Control System Upgrade for Warehouse Client
A fulfillment center needed to upgrade its obsolete system which was no longer operational. E Tech Group traveled onsite and overcame a multitude of challenges to get the client operational in their allotted timeframe.
The Project: Restructure a Down System Causing Delays & Disrupting Operations
An order fulfillment and warehousing client was facing significant challenges with an antiquated control system that was no longer operational causing them to fall behind schedule.
In an effort to bring it back online, they had previously engaged another automation services vendor, who had been working on the system for months without success. The client required the system to become operational urgently; further delays would keep them from meeting deadlines and impacting profitability. They turned to E Tech Group to expedite the commissioning process.
The Challenge: Limited Information & a Tight Timeline Leave No Room for Error
Attempting to pick up where another control system integrator left off isn’t the easiest, especially when any number of unknown variables can rear their heads at any time, as they did here. If not for the adaptability and diverse skill set of our automation team, they may not have been able to address and overcome those challenges.
- Limited Information and Timeframe: We were provided with only one week to study the current automation system, and the information available was limited, including the system’s description of operations and system rate.
- Lack of Equipment Design Information: No information regarding equipment design was presented, which made it challenging to understand all of the control system’s components.
- Limited Documentation: We were given some sample codes with minimal documentation, which made it difficult to understand and modify the existing codebase.
- Complex System Components: The system consisted of merges and a Print and Apply unit, adding complexity to the commissioning process.
- Absence of a System Checklist: There was no existing system checklist to guide the commissioning process.
The Solution: A Hands-On Approach Was Critical in Project Execution
Given the tight project timeline and the client’s immediate need, the engineering team decided to go onsite and commence development work directly at the location. This hands-on approach allowed us to overcome various challenges that could have manifested as delays:
- Addressing System Inconsistencies:
- Mechanical systems were found to be designed differently at different locations, requiring additional coding.
- The team needed to use the existing template, necessitating on-the-fly learning and adaptation.
- Inaccurate electrical wiring and layouts posed challenges that the team successfully addressed and resolved.
- Identifying Mechanical Inaccuracies:
- Correcting the placement of guard rails at scan points to ensure safety and functionality.
- Addressing issues related to non-uniform product conveyance within the system.
- Collaboration with Scanner Technicians: The team worked closely with scanner technicians, as the work they had performed previously was suboptimal. Multiple interactions were needed to resolve issues and ensure proper scanner functionality.
- Interconnections: Establishing interconnections with the upstream and downstream conveyors to ensure seamless material flow within the system.
- Checklist development: Due to the absence of an existing system checklist, the team created their own tailored checklist. This served as a fundamental tool in guiding their efforts during the system startup. It allowed them to break down the complex system into smaller, manageable sub-systems, ensuring a structured and efficient approach to the project.
The Results: Adapt, Overcome & Leave the Client With An Operational System:
Through the automation team’s presence onsite, expedited learning and development efforts, they successfully addressed the project challenges and got the upgraded control system up and running within the given timeframe. This achievement was a testament to the team’s adaptability, problem-solving skills and commitment to meeting the client’s urgent needs.
The client’s system is now and remains operational, meeting their immediate requirements and helping them avoid further delays. This project showcases E Tech Group’s ability to navigate complex and challenging scenarios to deliver results effectively and efficiently.
An efficient PLC and SCADA upgrade successfully minimized downtime, reduced costs, and improved the operational control of a tomato peeler system, enhancing product quality and competitiveness for a food manufacturer.
Challenge:
A prominent food manufacturing company specializing in tomato processing faced a significant challenge with their existing peeler system. The controls hardware was outdated, causing a higher risk of downtime, limited maintenance support, and poor controls performance and control network communications. The company needed to resolve these challenges and sought the support of E Tech Group. The food manufacturer chose E Tech Group for their proven track record and expertise in control systems, supporting a swift and successful automation project.
Solution:
The customer needed to upgrade their existing panel hardware for a modern EtherNet/IP control system. E Tech Group analyzed the customer’s existing system and provided the customer with a detailed plan to meet their specific needs of an upgraded system. This upgrade involved converting their existing Allen-Bradley PLC5 to the Rockwell Automation ControlLogix platform using the RSLogix 5000 programming environment. The customer also needed support connecting the ControlLogix platfrom to a new EtherNet/IP control network, converting several Powerflex VFDs with EtherNet/IP communications, and programming AVEVA HMIs and SCADA software for improved system visibility and real-time data monitoring. E Tech Group supported the system upgrade, retagging and remapping the existing logic to the new EtherNet/IP controlled hardware. The AVEVA HMIs and SCADA system were redesigned and programmed to provide the customer’s operators with better usability and improved access to critical data, ultimately enhancing their operational efficiency.
Results:
The project was completed on schedule, minimizing downtime. This led to significant cost savings as system failures were reduced. Improved control performance ensured smoother tomato peeler operations, enhancing the customer’s product quality. The enhanced system visibility enabled data-driven decisions and proactive issue resolution, reducing operational risks, and improving efficiency. Ultimately, this project supported the food manufacturer’s competitiveness in the market with a more modern control system.