Our Services
Breakdown Call Outs
At 303 Automation we know that every second counts in fast pace environments which is why we can offer breakdown assistance from knowledgeable engineers with a wide range of experience that goes a long way. Throughout our 14 years experience, a strong focus has been dedicated to breakdowns gaining the team valuable knowledge and honing the fault finding techniques and mindset. Over this time we have successfully rectified thousands of machine issues to get the machine back in production as fast and effectively as possible. Just a few examples of breakdowns we have experienced and rectified in our time, however the list is endless.
· 3 Phase motors failing
· Inverter Drives failing, replacing and retrofitting newer models
· Servo motor replacement
· Cable failures such as communication, multicore and servo drive
· Slip ring replacement
· PLC CPU or hardware failure and replacement
· Power supply replacement
· Cable replacement after a small panel fire to get panel back functioning
Software Consultation and Implementations
Software consultation and development of existing infrastructure to further improve and adapt how the system operates. Whatever the issue or improvement we can look to resolve the issue within the PLC program. We know firsthand that Manufacturers do not always get everything perfect first time and within the industry demands and needs change rapidly. This is why we can offer a consultation to gain knowledge of the current situation and then in turn provide support. If this is a simple PLC modification to change how the machinery works for improved efficiency and reliability, to HMI changes to allow operators greater visibility and usability and even retrofitting new devices to current systems.
A small selection of examples of projects that have been done include;
· Installation of quality measuring device, integrating this into the PLC hardware to talk over Profibus communications and allowing this to stop the machine automatically when the monitored value become out of specification and show an alarm on the HMI.
· Implementation of sleep mode control for conveyors systems the works from signals to receiving and sending machines as well as sensor feedback to shut conveyors down when the production line is in idle when empty or built back and automatically start back up once the line is back in production.
· Retrofitting of Danfoss inverter drive to motor with start delta starter to allow for better starting procedure, more efficient running and speed control as well allowing to enter a sleep mode quicker. This was several times with either Profibus communication to the PLC or via digital inputs and outputs
· Various format interlocks and automatic format selection on machines to reduce the risk of incorrect formats been selected by operators and allowing bad products to be made.
· Alarm board creation and integration for an area so operators can take a quick glance and the board when the siren sounds to know which part of the area is in fault rather than relying on individual machine sirens.
Panel Building
At 303 Automation whatever the system you are desire to create we can make a panel to suit your needs and standards. Simply provide a specification of what is needed and we will do the rest. All panels are all made to high degree of detail making for a reliable operation, easy to use and follow. All panels come with space for further expansion and clearly marked and documented terminals and wiring.
Panel Decommissioning
With the continuous fast pace that the industry and technology is moving, the need to keep up with this is paramount in reliable operation. This is why many businesses are implanting new systems to supersede obsolete equipment, however the newly redundant equipment can easily be overlooked during a project, taking up valuable space, creating a messy situation with no longer used cables and communications. This is why we can offer a decommissioning service for the now redundant kit with regards to the wiring, removal of signals in side various PLC codes allowing for the equipment to be safely powered off without effecting production and ultimately be fully removed from site. This making for a more efficient manufacturing system and easier maintenance.
Energy Saving Audits and Projects
Rightly so, energy saving is one of the most talked about subjects in any part of our lives at the moment. The spotlight is well and truly on businesses actively trying to save energy and becomes more sustainable businesses, not to mention the legal obligations that are only getting more stringent and the rising cost of energy. This is why we can provide an energy saving audit and project implementation service designed to identify any opportunities no matter how big or small to save energy, water or air. Through data analysis and metering we can provide a full breakdown of the savings created from the modifications allowing you to understand how much energy and money has been saved or is predicted to save.
Manufacturing Execution System (MES) Optimisation
For a number of years we have been the go to for optimising the MES platform on a large manufacturing plant. Data is key to improving a manufacturing system and if a MES system is not accurate and giving correct information, this can lead to not being able to maximise efforts to improve efficiency. This is why we can offer a service to improve the data accuracy of the MES systems in order to help diagnose the biggest losses on a manufacturing line. We have specialised in the Lineview system and become a subject matter experts, however we can optimise other MES systems just the same.
Line Balance
Line balance is often very over looked in the fast moving consumer goods section, however with this fast pace it is need that all machines and conveyors are working in synchronisation with each other. A line balance analysis looks at the certain attributes and parameter of the conveyors allowing for a report to be created in order to design a system that is more efficient at taking the product away from the preceding machine and getting to the next machine without causing issues. With this service we will monitor the production line over a long period of time creating a detailed report on how the system currently works in multiple different scenarios, to which we can then create an action plan to improve this product flow and minimise potential bottle necks in the system. This can be anything from simple PLC modification on the base the system works, or additional sensors added in to allow for better product tracking and therefore greater product control.