No Downtime? No Problem!
EAD’s client for this project is known for their global presence in package delivery, with worldwide operations that reach customers in over 220 countries. Intense competition makes this client aggressive in updating and maintaining their facilities. Package delivery requires facilities with reliable, top-of-the-line technologies to best perform their services.
The client initially hired EAD to design the upgrade of the controls automation systems at two of their package sorting hubs in New Jersey and Texas. The facilities functioned as a 24-hour operations hubs, posing a design challenge for EAD staff in that they were required to maintain adequate throughput of the sorting system while the conversion was underway. The scale and margin for error of this project also proved to be a challenge, but EAD’s operational flexibility overcame this obstacle by refining our deliverable production processes and enhancing our normally stringent quality control methodology. Additionally, when challenged with accelerating the design process, a condensed work schedule was successfully managed to provide accurate and timely deliverables.
This project replaced all PLC-5 and 1771 hardware with new ControlLogix and 1756 hardware. Planned in phases, it aimed to minimize downtime and mitigate the risk associated with bringing new equipment and programming online during a 24 hour-a-day operation. EAD designed the conversion to occur without any reduction in throughput to our client’s operations. The new automation design greatly improved the reliability of the facility. EAD continues to set the bar for automation modernization by leading a program of similar projects for many of this client’s package sorting facilities.