Automation and custom software
Takamura Japan
Automation retrofit with virtually no production lossxNet modernized Takamura's precast concrete slab production: from 1980s PLC technology through SiMon to directly integrated CAD software.
The starting point
Running production with control technology from the 1980s
Takamura in Japan needed to modernize the complete automation of a precast concrete slab production facility. The existing PLC and control technology dated from the 1980s, yet production had to continue reliably throughout the project.
At the same time, planning and production needed to be connected more closely. Design data had to flow into automated processes without unnecessary media discontinuities.
The system scope
From CAD planning to machine control
CAD planning
Production data
SiMon
PLC control
Production
The solution closely connects the purpose-built CAD application with SiMon and the renewed PLC control. Production plans can be transferred directly into the control system, creating a traceable digital process for planning, monitoring and production.
The implementation
Modernized step by step during scheduled non-production periods
Integrate the existing plant
The production facility and its established processes formed the binding framework for the modernization.
Renew the PLC technology
The legacy control was replaced step by step with a modern PLC solution during plant holidays, at weekends and at night. This kept production loss to a minimum.
Integrate SiMon
SiMon monitors processes in real time, provides analyses and supports intelligent alerting.
Connect CAD and production
The custom CAD software was closely linked to the plant control so production plans could be implemented directly.
The xNet solution
Automation, process software and CAD working as one
Automation
Renewed PLC control
The new control system provides a future-ready technical foundation and is the primary reason for the efficiency gain of over 30 percent.
SiMon
Optimize operating strategies further
SiMon makes states and processes transparent and enables optimized operating strategies as a foundation for further technical improvements.
Custom software
CAD connected directly to production
The industry-specific application digitizes the path from design to production and reduces manual data transfers.
The result
Over 30 percent higher efficiency from the new control system – further potential with SiMon
Measurably more efficient
The new control system was the primary driver of an efficiency gain of more than 30 percent while also improving process reliability.
Fewer sources of error
Direct transfer of production data reduces media discontinuities and avoids unnecessary manual data entry.
Further improvements enabled
Using the optimized operating strategies enabled by SiMon, subsequent modifications and additions to the plant technology could be implemented that would not have been possible with the legacy control system.
Project impressions
