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.   

1. 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. 
2. 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. 
3. Limited Documentation: We were given some sample codes with minimal documentation, which made it difficult to understand and modify the existing codebase. 
4. Complex System Components: The system consisted of merges and a Print and Apply unit, adding complexity to the commissioning process. 
5. 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.