Customer Problem:
A plastic regrind facility in North Carolina faced operational inefficiencies due to obsolete control systems throughout their entire plant. With nearly 30 control panels requiring updates, inconsistency in interfaces and functionality posed challenges for operators, leading to decreased productivity and increased maintenance efforts.
Think-PLC Control Panel Upgrade Solution:
Think-PLC collaborated with the customer to address the challenges through a comprehensive control panel upgrade initiative of almost 30 control panels. The project involved migrating diverse control systems, including older models such as PLC fob and Siemens S5, to a unified platform. The adoption of Siemens’ HMI template suite facilitated the use of a consistent interface across almost all machines, simplifying operator interaction and enhancing system predictability.
Results
The implementation of Think-PLC’s uniform standardization approach yielded significant results for the plastic regrind facility:
Enhanced operational efficiency through streamlined workflows and reduced learning curves for operators.
Simplified replication of standardized systems at the customers California facility, leading to extended collaboration.
Tangible financial gains with increased EBITDA over the past two years, highlighting the project’s impact on the bottom line.
This initiative not only modernized the facility’s control systems but also equipped it with advanced diagnostics capabilities, allowing for real-time troubleshooting and quicker response times. Think-PLC incorporated data analytics tools into the new systems, providing the facility with insights into machine performance and potential areas for further efficiency improvements. This data-driven approach helped optimize machine usage and minimize downtime, contributing to a more proactive maintenance strategy.
The enhanced system integration also allowed for better compliance with safety and environmental regulations, ensuring that the facility remained up-to-date with industry standards and reduced risk factors. With Think-PLC’s tailored solutions, the facility embraced technological advancements that not only bolstered their current operations but also positioned them favorably for future scalability and technological adoption.
Overall, Think-PLC’s intervention transformed the plastic regrind facility’s landscape from a collection of outdated systems to a harmonized, efficient operation poised for sustained success and growth.
