Brock Solutions supplies press line solutions to End Users, Service
Centers, and OEMs with interests in the Automotive, Applicance and steel
sectors. Our solutions focus increased product tolerances and
throughput.
The Challenge: Brock
Solutions was contracted by a leading North American automotive
manufacturer to design, develop, supply and implement new control
systems for three Footprint Press Lines in one of their stamping
facilities. The impetus behind the project was the customer’s need to
support the impending launch of new vehicle designs as well as to
accommodate ongoing customer demands.
The Methodology: As the first phase of the project, Brock provided a detailed
Functional Specification to outline both the hardware and software
features as well as functionality proposed for the design. Brock’s
Offsite Acceptance Test (OAT) using an I/O simulated environment ensured
the software was fully written and tested before site trials. In
addition, the OAT allowed the operators to experience a preview of the
design and its expected functionality.
The Scope of Work: Brock Solutions was responsible for the automation of the Presses, which included:
- Functional/Detail Design Specifications
- Controls PLC hardware and software
- Operator interface design and associated
hardware and software
- I/O Simulation
- OAT
- Start Up
- Commissioning
- IAT at mechanical rebuild facility
- FAT on site
The Benefits: At this stage in the project, the first Press (out of fifteen in total)
has been successfully commissioned and the following benefits acheived:
- Improved reliability of equipment and
production through-put capability
- Enhanced safety features
- Improved product quality
