Automation Assessment

 Improving Control Methods:

       Conversion of on-off controls to three-mode closed loop control

       Replacement of sensors with higher accuracy devices

       Use of less complicated operator devices

       Providing better information to operators to make decisions

  Capturing Efficiency Opportunities:

       Converting fixed speed motors to variable-speed (reduce energy use)

       Material handling techniques (valves, conveyors, etc)

       Incorporation of touch screens to reduce operator training/mistakes

  Improving Quality:

       Measurement of critical parameters

       Statistical calculations

       Predictive actions (stop machine before out of tolerance)

       Inspection of product (presence, absence, shape, color)

       Creating rejection/rework loops (conveyor diverters)

 Reducing Waste:

       Improving measurement and control of weight, length and volume

       Improving measurement and control of temperature, pressure and flow

       Improving measurement and control of speed

 Solving Operating Problems:

           Scheduling maintenance based on run time or parts made

           Annunciation of critical and non-critical alarms

           Providing electrical noise suppression to prevent nuisance shutdowns

           Use of machine to machine interlocks

           Reducing mechanical wear via control method and practices

           Upgrade obsolete control equipment

 Minimizing Energy Consumption:

           Monitoring for accounting cost allocation

           Non-critical load shedding to reduce KW demand charges and KWH usage

           Reducing oversized motors

           Power factor correction to reduce PF charges and KW demand charges

           Using “Smart” motor controllers to reduce KW demand

 Complying with Code or Safety Issues:

           Use of emergency stops

           Motor starter overload protection (group motors)

           UL rated devices

           Warning labels and safety lock-out devices

 Improving Manufacturing Information:

           Production Count

           Downtime monitoring

           Recipe management

           Production “Quality” parameters (temperature, weight, etc.)

           Remote site information