CRN: GrayMatter creates ‘next generation of solutions business’
October 15, 2024
ProjectX: Breaking Bottlenecks by Enhancing Efficiency in Polymer Manufacturing
The Problem
A polymer manufacturer faced significant challenges in enhancing its production capabilities at its facility. The company aimed to address bottlenecks in its operations by undertaking a comprehensive debottlenecking project.
The complexity of the project necessitated meticulous planning and execution, as it involved significant production line modifications, along with the installation of new packing equipment. The manufacturer required an experienced partner to ensure seamless integration of new systems while minimizing disruption to ongoing production.
Solution
GrayMatter was engaged to assist the polymer manufacturer throughout the debottlenecking project, which was structured into four distinct phases.
PHASE ONE
Design and Research
GrayMatter began by collecting the original designs for all machines involved in the project. An on-site assessment of each machine sought to verify the accuracy of existing designs.
Any discrepancies were marked for revision, ensuring that all design modifications accurately reflected the current state of the machinery while integrating new equipment seamlessly.
PHASE TWO
Offline Programming – PLC and Wonderware
Relying on the updated designs, GrayMatter made offline modifications to the existing Programmable Logic Controllers (PLCs). This involved adding new remote I/O racks and updating existing I/O points.
Simultaneously, changes were made to the Wonderware platform, including the addition of tags and the development of new user screens. Throughout this phase, GrayMatter worked with other equipment vendors contracted by the manufacturer to ensure compatibility and effective communication between the new and existing systems.
PHASE THREE
Installation and Commissioning
As the project moved into the installation phase, GrayMatter provided support to contracted electricians, addressing design questions and resolving any wiring issues that arose. Importantly, PLC logic updates were performed to align with the customer’s production schedule for unaffected lines.
GrayMatter tested all newly installed equipment to ensure proper integration with the existing PLC systems and updated the Wonderware application to reflect new functionalities.
PHASE FOUR
Production Support
Once production resumed, GrayMatter remained on-site to provide support, ensuring that all systems functioned as intended.
This allowed operators to ask questions regarding the new functionalities, and GrayMatter quickly addressed any issues that surfaced during initial production runs.
Results
The successful execution of the debottlenecking project led to significant improvements in the polymer manufacturer’s production efficiency.
The meticulous planning and phased approach ensured minimal disruption to ongoing operations. The integration of new packing equipment streamlined the packing process, ultimately reducing lead times and increasing output.
With GrayMatter’s expertise, the polymer manufacturer not only achieved its immediate production goals but also positioned itself for future growth by upgrading its control systems.
The collaboration highlighted the importance of experienced partners in managing complex industrial projects, reinforcing the value of strategic planning and execution in achieving operational excellence.