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QA TEST CELL HMI UPGRADE TO
VISUAL STUDIO - Designed and implemented
complete Visual Studio HMI based on our
Conferax™ rev. 3.1 OPC communications
library for a QA test cell on an air
compressor assembly line. The new system test
behavior is completely configurable from data tables
in a local SQL Server Express database, and all test
results are recorded and made available for
analysis.
SMELTER CHARGING ENVIRONMENTAL COMPLIANCE MONITOR
- Designed and implemented an automatic system to
check compliance with regulatory weight load
restrictions for a smelter operation. Prior to
system implementation all loads were recorded on an
electronic scale and reconciled by hand. The new
system automatically records each payloader, checks
for charge rate compliance, prints all regulatory reports automatically, and alerts the
shift supervisor when action is necessary. The
system relieves approximately ten minutes per hour
of shift supervisor time.
GROUND WATER
ENVIRONMENTAL REMEDIATION CONTROL
SYSTEM - Designed and implemented
a “lights out” control system for 30 pump
ground water level control plant. Subcontracted by an
environmental engineering firm to provide a completely
automatic system for controlling a pumping grid that
mitigates groundwater egression from a plant’s
grounds and sequesters
TCE and other VOCs within carbon vessels, the system is completely operable
via an internet connection or from a touchtone phone
via
dial in/dial out line using
our
Avizi™ rev.
1.7 alarm dialer interface. In the event of any alarm the
system automatically notifies and reports conditions
via phone, and can be commanded to take appropriate
actions based on user input.
WEB BASED PRODUCTION PLANNING
AND SAP INTERFACE - Designed and
implemented a production planning and material
utilization system with an add in module for SAP in
an aluminum products plant. The user interface is a
fully web server based design that allows planners
to simulate a number of “what if” scenarios with
resulting yield analysis prior to actual production.
The SAP interface module is a native SAP interface
module that utilizes the system’s yield calculator
to provide automatic BOM information for one off
sales. Preproduction plan comparison saves
approximately 40K lbs of aluminum per month.
AUTOMOTIVE ENGINE PLANT ROBOTIC
ASSEMBLY CELL - Designed and implemented
complete control system retrofit of a robotic diesel
engine valve adjustment system to COTS hardware.
Provided all mechanical, electrical, system logic,
and plant network architectural design and
installation plan from concept layout to final as
built package. Coordinated all equipment vendors and
supplied all craft labor for turnkey installation.
Responsible for insuring compliance for NEC and
local electrical codes for all control and power
installations. System’s robot control PLC monitors
assembly line control PLC for configuration
information, resolves appropriate sequence for valve
settings based on configuration, commands robot
sequences for specified sequence, and reports final
results including acceptance or rejection to QA
database in real time via custom SCADA interface
software.
EVAPORATOR/DISTILLER
- Designed and implemented control system for a two
stage test evaporator. The evaporator skid is
assembled with various configurations of heat
exchangers for each stage, and the control system
allows for independent operation of each stage or
operation in tandem to test product characteristics.
In effect the system is an industrial sized
chemistry laboratory. Testing product prior to
evaporator purchase provides assurance of product
suitability and information for proper equipment
sizing for final system target capacity.
WASTE STREAM REDUCTION BY OIL
AND PROTEIN RECOVERY - Designed and
implemented a waste water oil separation and
recovery system for a poultry slaughter house.
Provided all mechanical, electrical, and data system
logical and network architectural design and
installation plans from concept layout to final as
built package. Coordinated equipment vendors and
craft labor. Responsible for insuring compliance for
NEC and local electrical codes for all control and
power installations. Final system monitors raw
materials tank farm levels, controls product and
additive feed flows and steam injection into the
reactor tank, controls third party mechanical
decanter and centrifugal separators, and provides
control and indication of oil storage tank farm.
System provides resalable products from wastewater
and results in lower discharge volumes and
elimination of solid waste burial fees.
PAINTING AND CURING SYSTEM SCADA
- Upgraded and retrofitted an automotive OEM
aluminum wheel painting and curing plant to a fully
redundant SCADA system. Provided all mechanical,
electrical, and data system logical and network
architectural design and installation plans from
concept layout to final as built package for upgrade
work. Final control system consists of five Allen
Bradley SLC-5/05 controllers, five operator station
SCADA nodes, two fully redundant SCADA servers with
complete failover capacity, and two fully redundant
SQL server nodes with complete failover capacity.
All recipe management and QA production data are
stored in the SQL servers, with Allen Bradley PLCs
controlling all conveying, painting, and curing oven
operation. System upgrade provides 100% uptime for
manufacturing and real time QA data.
SUPERVISORY SYSTEM RETROFIT
- Designed and integrated a coordinated data
acquisition and production tracking system for
multiple vendor SCADA systems using Factory Link and
Wonderware as a single unified system using MS-SQL
Server as a back end repository and custom designed
MS Visual Studio applications as coordinating
applications for a steel rod mill. Provided all data
system logic and network architectural design.
System upgrade provides real time and historical QA
data from various SquareD, Modicon, Allen-Bradley,
and Fanuc controlled lines.
PAINT BOOTH AIR QUALITY MONITOR
- Designed and integrated a personnel safety air
quality monitor for an assembly plant paint booth.
System monitors various gas monitoring modules for
user definable limits, and initiates personnel
evacuation alarm and automatic purge when outside
defined operating parameters.
ASSEMBLY LINE RETROFIT FOR
FLEXIBLE COMPUTER INTEGRATED MANUFACTURING
- Designed and implemented a retrofit for a manually
scheduled batch build automotive sub assembly line
into a flexible computer integrated manufacturing
line with automatic demand scheduling from an Oracle
Financials Order Entry system. Responsible for all
Data Models based on Unified Modeling Language (UML)
2.0 standards. Provided all data system logic and
network architectural design. Daily reporting
facilities provided throughput, cycle time per
station and per assembly operation, operator
efficiency, reject reporting, and material
utilization. Central SCADA systems provided complete
operational facility of the assembly line and
modification of the build schedule. Individual build
station interfaces provided assembly instruction and
part identification information to the operator.
Part location and pick lights and pick verification
were captured to the database. All error proofing
checks and QA verification checks traceable to
individual serial number and operator.
CERAMIC PLANT MANUFACTURING
EXECUTION SYSTEM - Designed and
coordinated implementation of a comprehensive SCADA
and Manufacturing Execution System for thirteen
equipment vendors for a three year $25 million
ceramic varistor plant expansion. Responsible for
all Data Models based on Unified Modeling Language (UML)
standards; coordinated all vendors’ PLC and HMI
programming staff for each machine cell; coordinated
Industrial Informatics staff for all scheduling
interface and reporting programming. Provided all
data system logic and network architectural design.
System provides complete flexible scheduling and
both historical and real time QA data.
AIR COMPRESSOR TEST STAND
- Designed and implemented a 12 parameter QA Final
testing cell in an Air Compressor assembly line.
System design tested peak pressure, pressure vs.
time, leak rate, and shaft input power in three
operational modes, then accepted or rejected the
unit. Accepted units were tagged by serial number
via a Wonderware SCADA system, and both accepted and
rejected units were recorded in a QA database.
System provides 100% part testing and historical QA
data.
INJECTION MOLD PRESS
MANUFACTURING EXECUTION SYSTEM -
Designed, integrated, and started up a Wonderware
SCADA to Sybase SQL Server product data collection
and production reporting for a 24 node
multi-platform rubber injection molding facility.
Provided all data system logic and network
architectural design. Original facility consisted of
8 isolated molding stations controlled by TI-505
plc; final configuration implemented full network
production monitoring, machine downtime analysis,
operator time and attendance validation, centralized
scrap recording to flag mold retooling needs on the
original 8 station plus 16 new stations utilizing a
mix of Siemens and Modicon PLCs. System provides
real time and historical production data.
MEDIUM DENSITY FIBERBOARD LASER
MICROMETER INTERFACE - Designed and
integrated an operator display system to capture
real-time data from a previously installed bank of
laser micrometers to present surface parallelism and
RMS flatness in real time to the production
operator. System allowed adjustment of press
parameters to reduce scrap.
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