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Sure Controls

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Sure Controls

  1. 1. Plant Automation To Make You Sm;)e 1 We provide industrial process solutions with enthusiastic services & automation products that enable “World Class Manufacturing”
  2. 2. Plant Automation To Make You Sm;)e About Us • Founded in 1984 • Privately Held • Located in Greenville Wisconsin • Global provider of products and Services – Recent projects in Wales, France, and Mexico – Products distributed in US, Canada, and Europe Greenville Our Mission: Delighting Our Customers With Design Foresight, Product Leadership And Unequaled Responsiveness • Currently Occupy 18,000 Square Feet • Thirty associates bringing over 200 years of experience and expertise to market 2
  3. 3. Plant Automation To Make You Sm;)e Sure Associates Sure Associates are dedicated to “Delighting Customers with Design Foresight, Product Leadership and Unequaled Responsiveness”.
  4. 4. Plant Automation To Make You Sm;)e Engineered control systems to : • increase safety • Improve product quality • Increase productivity • Reduce power consumption • Reduce down-time Sure Controls designs, builds, installs and tests control systems to enhance safety, quality and productivity. Sure Controls’ project management assures lower risk and excellent communications so you know project status exactly. We understand your production processes so we can design solutions enabling you to meet your goals without over engineering. EXAMPLES OF SURE CONTROLS INC. INTEGRATION PARTNERS Sure Services Integration Solutions 4
  5. 5. Plant Automation To Make You Sm;)e Designing new or rebuilding existing panels; our team of experts produce quality solutions that makes maintenance easier. We offer: • UL certification • CE compliance • Factory tested Your design or ours, we take the time to assure the project makes ‘electrical sense’ at every turn while being reliable, compliant and easy to trouble shoot. Sure Controls can also take existing electrical schematics with redlines and produce clean new documentation reflecting the current state to minimize downtime. Sure Services Control Panel Design and Production 5
  6. 6. Plant Automation To Make You Sm;)e Automated data collection and analysis (SCADA) allow you to make informed decisions that lower costs, improve quality and safety. Ask us how! • Capture data reliably in real-time • Access the data real-time • Automate reporting saving analytical time • View data and machine status locally at the machine, from your desk, or on the road from your mobile device. • Plant floor visualization – key performance indicator and metric reporting Sure Services Plant Intelligence Solutions 6
  7. 7. Plant Automation To Make You Sm;)e • Prompt friendly service for troubleshooting • Preventive maintenance • Certified calibration services • 24/7 telephone access for scheduling. We call them enthusiastic services because our technicians understand the urgency and importance of increasing runtime and quality. Our goal is to return you to service as quickly as possible We offer: 24/7 telephone access for scheduling Remote troubleshooting services Sure Services Field Services 7
  8. 8. Plant Automation To Make You Sm;)e Repair Services: Not sure whether to repair or replace? Worried about how long it takes? Let Sure Controls experts assess your part. We’ll tell you if it costs less to replace than repair so you’ll know. Ask about our exchange program. Training Services: Your place or ours. Train on the same equipment you’re using hands on! Give your team more confidence and the ability to get you back into operation when problems arise Sure Services Training and Repair Services 8
  9. 9. Plant Automation To Make You Sm;)e Electromechanical Example • Pick and Place Gantry Style Robotic Integration System • Turn-Key o Pick and place system o End Effecter (gripper) o HMI o Mechanical support structure o Commissioning & Install 9 Concept Completion
  10. 10. Plant Automation To Make You Sm;)e Example System Solution • Parker provides mechanical sub-systems to solve material handling applications including... o Palletizing o Storage and Retrieval o Machine Loading o Parts Transfer o Automated Assembly
  11. 11. Plant Automation To Make You Sm;)e Safety Achieve compliance with OSHA guarding and safe stopping regulations • Interlocked guarding switches, using guard safety relay • E-stop circuits updates with E-stop safety relay • Machine E-stop functionality: Fast stop, followed by power removal • Safety devices and circuitry at EN954 Class I safety standards
  12. 12. Plant Automation To Make You Sm;)e Safety Applying design methods to meet ArcFlash requirements • Door mounted devices for ease of maintenance • Panels designed to meet SCCR needs • External disconnects achieving full power removal inside cabinet
  13. 13. Plant Automation To Make You Sm;)e Safety Safety circuit updates • Meets industry standards • Capability of installation in hazardous locations • Engineered quick stop, then motor power removal
  14. 14. Plant Automation To Make You Sm;)e Motion Control Example 1 Two axis conversion from hydraulic to AC motors o Increased production rates by nearly 2X o Significantly reduced downtime associated with hydraulics o Improved process capability – can now process materials that couldn’t be done in the past
  15. 15. Plant Automation To Make You Sm;)e Motion Control Example 2 Three axis web handling application DC to AC o Eliminated obsolete drive equipment o Improved processing capability o Addressed ARCFlash needs o Reduced motor PM requirements Before After
  16. 16. Plant Automation To Make You Sm;)e Motion Control Example 3 Nine extruder drive conversion o Eliminated obsolete drive equipment o Improved processing capability o Addressed ARCFlash needs
  17. 17. Plant Automation To Make You Sm;)e Motion Control - New Machine New 15 axis machine – AC Motor Control • Pre-installation verification • ARCFlash ready • Quick machine field commissioning
  18. 18. Plant Automation To Make You Sm;)e Motion Control - Servo Supplied mechanical and electrical products and engineering to perform two axis injection control… o High precision positioning o Runs open or closed loop
  19. 19. Plant Automation To Make You Sm;)e Motion Control – Fan/Pump Replaced existing across the line motor starter with V/Hz drive and closed loop with process feedback… o Qualified for rebates from Focus on Energy o 9 month payback on utility costs alone
  20. 20. Plant Automation To Make You Sm;)e Motion Control – Conveyors Designed automation system for corrugator conveyor… o UL Panels o Auto/manual functionality o Multiple stack configurations
  21. 21. Plant Automation To Make You Sm;)e Motion Control – Conveyors Designed automation system for corrugator conveyor… o Monitor barcodes on stacks o Strap stacks according to size based on barcode
  22. 22. Plant Automation To Make You Sm;)e Other Motion Experience • Updated DC drives on: o Web handling (unwind, rewind) extrusion line in Mexico o 17 axis web handling line o 26 axis web handling line • Converted DC drive/motor to AC: o Multiple 200-300 HP extruders o Material handling process equipment (paper, plastic, wire)
  23. 23. Plant Automation To Make You Sm;)e Machine Control – PLC Upgraded Siemens S5 PLC to AB Control Logix • Ability to repeat functionality (requires understanding of both platforms) • Eliminated obsolete parts • Self-sufficient maintenance • Ability to move process/production data to network Before After
  24. 24. Plant Automation To Make You Sm;)e Machine Control – PLC PLC System Upgrade • Engineered/pre-wired in shop to meet minimum downtime requirements • Assisted in field installation and commissioning providing 24 hour coverage
  25. 25. Plant Automation To Make You Sm;)e Process Control Upgrade Upgraded obsolete MACO system to Eurotherm discrete w/comms • Ease of maintenance • Redundancy for operator setpoints Before After
  26. 26. Plant Automation To Make You Sm;)e Process Control Upgrade Upgrade temperature control using RKC SRZ system • Low cost • Ease of connectivity for process data mgmt • Small form factor
  27. 27. Plant Automation To Make You Sm;)e Process Control Upgrade Complete Drive, Temp, PLC and HMI upgrade of Sheet Line Before After
  28. 28. Plant Automation To Make You Sm;)e Operator Interface Update of a legacy system using the latest technology, yet able to maintain the ‘look and feel’ the operators were used to- thus minimizing impact of transition time. Before After
  29. 29. Plant Automation To Make You Sm;)e Quality & Metrics The Challenge: To turn daily hand written run reports into real-time, accurate data measuring downtime and associated reasons for each occurrence.
  30. 30. Plant Automation To Make You Sm;)e Quality & Metrics Using an operator interface coupled with machine I/O, barcode scanners and on-screen keyboard to collect the data…
  31. 31. Plant Automation To Make You Sm;)e Quality & Metrics …We were able to bring rich web-based reports to the management team to help fuel their decisions.
  32. 32. Plant Automation To Make You Sm;)e Quality & Metrics What did our customer get • $$$ - (12 month payback) o Energy costs (estimated at $10K/mo) o Fewer operators (estimated at $100K/annually) o Fewer data entry clerks (estimated at $60K/annually) • Increased Productivity o By developing goals for machines and specs and holding operators accountable o Able to respond to very accurate data concerning downtime and waste • Visibility o Easy access to the production data by all users over the Web
  33. 33. Plant Automation To Make You Sm;)e Putting Our Customer in Front • Delivering a ‘superior experience’ • Single queue Customer Care email • Tech Support team to help with obsolete or hard to find products • 24/ 7 Telephone Response • Experienced engineering to help you design your solution • Field sales professionals • Monthly customer satisfaction measurement – Web-based Survey every month • WWW.SureControls.com – Information | Contact | Technical Information | Communication
  34. 34. Plant Automation To Make You Sm;)e Our Commitment • We partner with you to solve challenges you are currently facing. • Our experts are available to: o Listen to your needs o Design the right solutions o Deliver turn-key integration that meets your requirements 34

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