News & Knowledge

We’re your source for automation news. Keep up with the latest industry updates and E Tech employee spotlights, as well as tips and guidance from our manufacturing experts.  

How to Perform a Risk Assessment  

– By Tony Schalk, Functional Safety Engineer (TÜV Rheinland), Automation Systems Engineer, E Technologies  Sophisticated companies know that safety is a journey, not a destination. It is a part of their strategic and ongoing growth. As more and more companies look to implement safety programs, questions about budget, time, effort, and feasibility come into play. Larger companies may already employ a safety engineer or even a safety team, with well-established metrics and objectives each year. If you don’t fall into that category, don’t be discouraged. The most important thing you can do on any journey is to start. To begin your safety journey, you start with a risk assessment.   In the United States, when an accident originates from machinery, the owner of the machine is responsible for the safety, not just the manufacturer of the machine. This means that if something happens, it’s technically your responsibility. If that doesn’t scare you, it should.  The beauty of the risk assessment is that it is your education on what could happen with the machinery in your facility. What you choose to do with your newfound knowledge is up to you; however, in the immortal words of G.I. Joe, “Now you know, and knowing is half the battle.”   There are a few caveats. Although companies could self-perform their risk assessments, it isn’t a job that just anyone in your plant can do. A TÜV certification is needed, as well as an understanding of ISO 13849 or IEC 62061 standards. Anyone could pick up the standard and follow the process, but it’s hard to implement a standard and its many details if you’re new to safety. This is where having a safety professional can be very beneficial for efficiency’s sake. He or she can walk into a situation and quickly identify what needs to … Continued

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Returning a Roll Coater Paint Line to Maximum Profitability

Our automation engineers expanded line capabilities and upgraded to state-of-the-art Siemens digital drive systems to support a leading steel company.

Project: Bring Existing Automation Tech Back Up to Specs

A leading steel company hired E Tech Group to expand their line’s capabilities to begin production of light gage steel, as well as increase throughput on existing operations by upgrading an existing roll coater paint line to return it to the OEM specs of 1600 fpm.

Solution: Evaluate and Optimize the Automated Equipment’s Capabilities

To accomplish this, E Tech group conducted an equipment audit to determine 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.

Our engineers 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: Unmatched Line Speed, Way Less Downtime

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 Tech Group expanded the line’s capabilities to include the production of light gage steel.

As one the nation’s leading control system integrators, E Tech Group is a multifaceted automation company offering the best in process automation solutions to manufacturers across industries. E Tech Group has experience in the metals, chemical, machine building/OEM, pharmaceutical industries, and more. Our turnkey factory integration services provide clients with robust, cutting-edge control systems that adapt, scale and optimize your processes.

Exit Line Automation and Controls Upgrade

An American industrial company specializing in aluminum products contacted E Tech Group to upgrade their exit line automation and controls. The line had previously been running on vintage reliance analog drives from the ’60s.

The Project: Bring Facility Automation Capabilities into the 21st Century

The project was divided into two phases: hardware design (including design work for a new Portable Control Room) and a phase to build, install and, commission.

Documentation and drawings presented a challenge in this project. With a 50-year-old system and an inconsistent approach to drawing updates and documentation, E Tech Group used biweekly conference meetings to keep the team informed on status and request additional drawings and information from operators and maintenance personnel as needed.

The Solution: Replace Analog Drives with Siemens System Integrators

E Tech designed and commissioned a new PCR, Siemens drives, encoders, process automation controllers, and IO panels. PanelView terminals were installed for operator interface and display. The elongation control system was replaced with modernized controls.

To enable seamless integration of the new technology with the line’s older equipment, E Tech Group’s automation engineers interfaced the new controls with existing legacy analog drives and hardwired relays to confirm that the new system operated in lockstep with the legacy control system prior to commissioning.

E Tech Group’s engineers wrote the drive interface to be transparent to operators and maintenance personnel with a focus on long-term maintainability and improved troubleshooting capabilities.

The Results: Exceeding Client Expectations, but Not Budget or Timeline

Startup and commissioning were completed ahead of schedule. As such, the project came in under the installation and commissioning budget originally quoted. Because of the transparency to the operators, the integration was seamless.

Moving forward, this new integrated control system will save the client money via increased production capacity, as well as reduced malfunctions and subsequent downtime. Even better, E Tech Group engineers designed this control system in a way that will lessen the client’s need to contract outside IT troubleshooting and system maintenance.

Enabling our clients to perform at their best both now and in the future as they grow is at the forefront of our mind in every control system build, upgrade or retrofit. E Tech Group provides disruptive automation strategies with the best automation products in the industry to create robust, integrated control systems that help you reach your goals.

Emergency Support Call and Upgrade of Steel Mill Line Controls

After a steel mill client experienced a flooded basement and damaged equipment, E Tech Group upgraded the obsolete drives, PLC, and HMI, as well as an automatic tension control mode.

Project: Increase Production Capacity and Shore Up Safety

A leading steel company hired E Tech Group 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: Follow the Audit’s Recommendation in Control System Design

E Tech Group conducted a mill drafting study to determine HP and speed limitations, reviewed the mill model, and set up proper procedures. We conducted an equipment audit to determine the failure rate and root causes, before implementing the audit’s recommendations.

E Tech Group’s control system integrators implemented:

  • Monitoring and tuning of the inner stand tension
  • An MG set stand
  • One custom 12 pulse drive to fit on existing gen base
  • A screw-down clutchless control.

We also regulated the voltage to the speed reg. Our automation engineers then performed a safety study and implemented recommendations. We performed installation, startup, and commissioning of all relevant systems.

Results: Real-World, Real-Time ROI via Improved Safety Automation

This successful project accomplished several things for the client:

  • Reduced head and tail off-gage
  • Reduced strip breaks, WR, and BU roll wraps by 50%
  • Improved strip shape
  • Increased annual tonnage
  • Reduced electrical downtime by 50%

As such, this project resulted in a quick ROI for the client, with whom we have worked on other control system upgrades and retrofits since. E Tech Group offers metal manufacturers automation solutions of any size, from integrating a single piece of equipment to providing facility-wide control system builds or upgrades. Our breadth of experience in the industry provides us with the specialized knowledge needed to create intuitive automation systems that set our clients up for success.