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.  

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Remedying Delays & Downtime for Global Leader in Logistics

A global courier was facing delays and fines caused by an aging system. E Tech Group performed a complete overhaul of the operational infrastructure and added on-call support, eliminating all delays post-implementation.

The Project: Perform a Complete Retrofit that Eliminates Errors

A global leader in logistics and courier services located at an airport hub was experiencing routine equipment failure as their SCADA environment would freeze, crash, stall, and disrupt operations on a nightly basis. In some situations, the IT team had to restart the server environment to get the system to function. 

They and the airport sort packages overnight between 11pm – 5am. So as soon as the planes land, the packages need to be taken off the plane, trucked to the facility, sorted, and placed back on another plane. All this needed to be completed before 5am so that planes could take off before 6am.  If the planes didn’t take off before then, it would disrupt commercial operations and they would be fined $100k per plane.

The old system causing delays combined with the large number of packages during peak season would routinely push them past that 6am deadline, resulting in hefty fines. They were hemorrhaging time, money and reputation by the day.

The Solution: Restructure, Update & Support an Aging System

Our team of automation integrators determined an overhaul of their operational infrastructure, and the addition of on-call support would be the best solution.

E Tech Group upgraded the server environment and the software, corrected major programming errors, and supported the SCADA environment.  These combined solutions eliminated the delays and fines. Due to the large scale and volume of the facility, E Tech Group worked in tandem with the client to provide continued support around managing the servers, operation updates, and providing 24/7 on-call support. 

The Results: Exactly Zero Delays Experienced Post-Implementation

Since implementing the 24/7 on-call emergency SCADA support, the client has never been delayed. 

The client was so pleased with the success of this upgrade and support contract that they have asked E Tech Group to tailor and scale this custom process automation solution across multiple US and European sites.



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Maximizing a Distribution Center’s Capacity with Custom PLC Software

A global parcel services provider needed a custom PLC program for their sortation systems. E Tech Group provided PLC program development, troubleshooting and system start-up to meet a tight timeline and improve productivity.

The Project: Improve Efficiency with Material Handling Automation

E-commerce growth and expedited shipping demands have posed challenges for distribution centers. To keep up, many centers are implementing automation solutions to maximize throughput and reduce fault recovery time.

A global parcel services leader outsourced PLC program development for their sortation systems, but faced a tight timeline. E Tech Group was hired to quickly develop and troubleshoot the programs, as well as lead system startup and testing.

The Solution: Create a Custom PLC Sorting Solution

The parcel operations required extensive fault monitoring and suppression, as well as package flow rate tracking, to maximize throughput and reduce system downtime. E Tech Group prioritized the commission of the primary sorter systems, including diagnosing and correcting errors and setting up communication between the PLC and the customer’s warehouse management system. They also set up numerous conveyor belts that were required to run with the package tracking logic.

The Results: Maximized Operations on a Quick Turnaround

E Tech Group completed changes to the primary sorter systems and stayed on board to support testing and commissioning of the remaining parts of the primary sorter line. With our programming support, the system became fully operational within a few months. This helped the parcel services leader to maximize its large-scale distribution center operations. As a result, E Tech Group was later invited to lead the development, startup and testing of the second phase that included an additional five sortation systems.


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How to Ensure Useful Data Extraction from a PI Historian System 

Data is an ever-present and growing benchmark in all industries. However, sometimes it may feel like it’s cloaked in mystery. There’s often a question of, why is collecting process data important? You then start to go down the rabbit hole trying to answer…..How do you get data out of your equipment? How do you decide what to collect? After assessing the previous questions, how do you test, and if necessary, validate that all of that data is being collected as expected? Understanding a holistic approach to data collection and validation from an AVEVA PI Historian System can help provide a high-level, big picture understanding to the importance of process data. With more than 10 years’ experience as a group engineering manager, Matt Martin has a depth of experience with integrating AVEVA PI Systems within sites of various sizes – here’s what I’ve learned: Why is the Importance of Data Increasing?  The “why” question is the easiest one to answer. Everyone can agree that in the era of modern manufacturing, extracting data from your manufacturing processes is critical to a business’s success and ability to grow. This includes every level of production and management: Provides the operator at the plant floor level the ability to adjust and better control the manufacturing process on the fly Allows engineers better insight into trends and behaviors of the overall process to improve designs from both a throughput and efficiency standpoint Produces KPIs (key performance indicators) for managers and executives to assist in their decision making Having large representative data sets is becoming even more important with the advent of AI and more specifically machine learning. Allowing these technologies access to your systems data helps identify patterns, overall system behavior, and correlations that were previously near impossible for the human eye to uncover.  Now, How … Continued

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Building an Automation Infrastructure

E Tech Group Director of Operations, Cassy Gardner, is featured as a part of the following article, which originally appeared in Food Engineering Magazine. The better you know what you already have in place, the easier it is to plan for a successful future. Unless you operate a brand-new state-of-the-art plant, you probably have a facility with a mish-mash of aging processing and packaging equipment with various vintages of network and application software support—maybe several areas still requiring manual labor. As technology continues to move forward, piecemeal, aging automation systems reach a bottleneck, hampering further growth and competitiveness for the company. For older facilities, knowing where and what to automate—what your priorities should be—is important to helping you stay competitive now and in the future. For those with new plants, it’s never too late to plan your future goals – today’s turnkey automated factory is tomorrow’s control system retrofit. In this article, we consider how to know when, where and what to automate in an older facility. Of course, the answers to these questions won’t be the same for every plant, but we can see a framework essential to all automation projects come through regardless. Automation Solving Labor Shortage Problems The primary motivations driving food processors to automate their operations include labor reduction, increased production efficiency and enhanced product quality, says Ryan Beesley, CAP, Regional Engineering Manager at Kennewick, Concept Systems, Inc., a Control System Integrators Association (CSIA) Certified Member. But the labor aspect has especially been an acute problem for the last couple of years as manufacturers realize the labor shortage is not a short-term problem. Other Advantages of Process Automation Getting Started in the Planning Process No two automation solutions will be the same—each one is unique. “Custom automation solutions typically begin with a feasibility and concept phase … Continued

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