Last year we where in Leicester. Replacing conveyor weigh controllers that manage the dosing of bulk aggregate materials.
Standardisation
Standardisation is the word of the day. Over the years, this plant has undergone some slight evolution, and somehow, has different versions of SEG weigh controllers. While this isn't ordinarily a problem, when it comes to training new staff, that's 2 systems they have to learn. In the modern world, employees don't tend to stick around like they used to. There is a debate to have as to the reasons why, but that's for another day. It's few and far between you find employees serving >10 years service. That means that when those experienced workers leave through retirement or to pastures new, the challenge starts to onboard and train new team members. Now you might think that learning 2 different control systems isn't the end of the world, but couple that with a site built on around 100 acres of land, filled with complex manufacturing equipment and things can start to get a little daunting!
We find it best to simplify, and standardise. The less that your employees have to learn the better. Does the added complexity add any extra value? If the answer is no, or very little it may be time to streamline the process. This is exactly what this manufacturer did.
Out with the old SEG T3, V3's and in with the new A2 Models.
This particular setup is controlled by a central machinery PLC, meaning the PID
loops are not in use and the weighers are simply passing a signal from the load
cells to the PLC. This means that all data can be managed and displayed via HMI
touch panels throughout the factory. The quality critical parameters can be
viewed but not modified by everyone on site, easily and at a glance! Those that
need to, can adjust parameters by secure means, in this case username and
password. Alarms have been programmed to alert operators that tolerances are
going out, and automatic shutdown of the plant is possible when the tolerances
go outside of preprogrammed limits.
All of this was carried out to prevent unauthorised changes
to recipes and prevent the accidental tare or "zeroing" of a conveyor
belt loaded with material. If your experiencing human errors that are impacting
your process quality, reach out today to see what we can do to help you!
