CASE STUDY
Capabilities Demonstrated
The Client:
Automotive Line Builder- automotive manufacturer end-customer
- Factory Automation
- New equipment automation
- Electrical design
- Panel Fabrication
- PLC programming
- HMI software development
- VFD installation / integration / configuration
- Construction management
Problem
An automotive manufacturer required a new paint line to increase production capacity and efficiency while improving absorption and removal of contaminants and environmental emissions. The new system required air houses (air houses provide filtered/conditioned air for work space and paint booths and also filter/remove fumes and gases for quality).
Solution
SkyIO was contracted by the line builder to provide the control system automation for the paint process air houses.
SkyIO delivered the process control system, handling the automation, design, control panel fabrication, construction management, installation, and commissioning of the entire system for motors, instrumentation, and controls.
Results/Outcomes
- Increased manufacturing capacity
- Improved manufacturing efficiency
- OEE / downtime-critical
- More consistent product quality
- Safety-focused implementation
Project Overview
Automotive manufacturing is extremely schedule-driven, requiring planning and flexibility. At times working around the clock, managing multiple electrical contractors and schedules.
Five (5) electrical shops were contracted by SkyIO to maintain project pace.
The line builder provided P&ID’s, functional specification, building/general arrangement layouts, and all mechanical installation.
SkyIO developed the associated design docs & required PLC code, leveraging customer-supplied modules as building blocks.
SkyIO designed and manufactured over 100 control panels.
SkyIO provided installation bid packages, secured, and managed the controls and electrical scopes for installation, commissioning, and startup.
Software Developed
- HMI and PLC-based paint process air house control software
Hardware Utilized
- Siemens S7 PLC
- Siemens ET200SP Remote I/O
- Danfoss VFDs
- Endress and Hauser Instruments
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