The benefits of hiring a system integrator with robust project management methodology for high-speed execution and high-quality solutions
Challenge
A major food manufacturer needed a system integrator to design and fabricate six control panels for their new production line. They chose Automation Group because of their expertise in building UL 508A control panels, ability to source hard-to-find parts, and capability to create alternative solutions to meet tight project deadlines. The customer needed a fast project execution and a customized solution with Automation Group’s streamlined panel build process leveraging AG5 project management methodology. Automation Group rose to the challenge, constructing six UL508A control panels with speed, quality, and engineering integrity to support the customer’s new production line.
Solution
A main challenge was to ensure the project remained on schedule due to long lead items to PLC components, such as safety PLC modules, VFDs, and other control components. Automation Group leveraged their efficient panel build process and AG5 project methodology to create a viable solution for the customer across five key phases:
Phase 1 – Collaborate
Following a technical Q&A with the customer and creating a bill of materials, Automation Group’s project manager collaborated internally with their purchasing department to review project materials and potential long lead items. Long lead items were ordered to ensure the project timeline was not impacted.
Step 2 – Design
Next, Automation Group’s engineering team created the control panel design, defining the system requirements, developing a device and I/O list, and creating the panel schematics. Every detail is considered and carefully planned to support proper functionality when the control panels are later assembled. Automation Group’s engineers and drafting team approved the panel design with engineering leadership as part of the system integrator’s internal quality control procedures before it proceeded for customer approval. Automation Group’s purchasing department then ordered all parts to support the multiple control panel builds and quickly informed the project team of unavailable materials to discuss possible alternatives with the customer. Automation Group’s project manager and engineering team worked with the customer to create a viable solution with compatible alternatives and then the team regrouped internally to source those alternative hardware options with the purchasing department.
Automation Group understands that the collaboration and design stages can impact the next phase of a project – building the control panels. Attention to detail and quality control measures lead to faster and higher-quality project outcomes, which is why the first two phases act as a foundation to deploying a well-executed project.
Phase 3 – Build
Once the schematics were completed and the components were received, Automation Group began building the control panels at their large-scale panel shop in Modesto, California. The panel shop team assembled the six control panels to the customer’s specifications and to comply with UL 508A standards. The panels integrated CompactLogix 5380 Controllers with POINT I/O Safety I/O Modules, PowerFlex 525 AC drives, and Panel View Graphic Terminals for visualization.
Phase 4 – Test
Automation Group’s panel shop team carefully evaluated each aspect of the assembly process to ensure it complied with safety requirements and functions as intended. The panel shop team performed several evaluations, including point-to-point testing, and produced documentation for the customer of how the control panels were built in collaboration with Automation Group’s drafting team.
Phase 5 – Deploy
With the control panels thoroughly tested for complete functionality, Automation Group prepared and shipped the control panels to the customer’s site for installation.
Results
Automation Group’s multidisciplinary team showcased exceptional results in their project execution, completing the project 4 weeks ahead of schedule. Through seamless collaboration and leveraging diverse expertise, the team achieved high-speed project completion without compromising quality. Their coordinated efforts expedited the timelines, resulting in significant time and cost savings for the customer. The emphasis on maintaining high standards throughout the project lifecycle ensured the delivery of quality solutions, ultimately leaving the customer highly satisfied with the outcomes achieved for their new production line.
