Driving Innovation with Enhanced Operational Efficiency

SITUATION

A steel manufacturing hot mill had an urgent need for two Automation and Controls Engineers. The mill is in a very remote location, and the client had recently severed ties with their OEM supplier for automation and controls support. This was the first time the client ever hired a contract resource.

SOLUTION

In less than two weeks, we were able to provide two consultants. In just three months, they fixed hundreds of machines in the plant throwing codes and interrupting the manufacturing process. The consultants completed the following tasks:

• Working in TIA Portal, they debugged systems and enhanced efficiency for the Finishing Mill, Rolling Mill, and Caster Mill.
• They improved user face and operational clarity by customizing HMI.
• They enhanced system responsiveness by integrating remote panels into alarm systems.
• They captured and analyzed iBA data for machine learning applications.

RESULT

Our consultants came into a plant that was not functioning efficiently and got it up and running immediately. Their efforts helped drive innovation and ensure all machines were operating at full capacity. They were able to resolve all the issues and help train on-site staff to ensure the problem would not reoccur. The client said if we had not stepped in, they would never have been able to recover.