Using automation to streamline processes
A leading fortune 500 cereal manufacturer depended on manual labor and storage tanks to address a mismatch in the speed and timing of their facility processing and packaging lines. Because one line was slower than the other and frequently went down, the manufacturer had to reduce the efficiency of the second line so that the two lines could operate in-sync.
EAD engineered a controls solution that reconfigured how the cereal lines were conveyed throughout the system. Using just one engineering resource, EAD was able to complete the programming of the new configuration one week ahead of the client’s schedule. Implementing the final solution took only a few hours, since there were no programming errors.
EAD’s controls solution not only reduced the need for manual labor, but it increased the client’s production of cereal by 33,000 pounds over the daily target. Although our client had allocated $12K of their budget towards the project, EAD’s solution and accuracy reduced this cost by $3K, enabling the client to use the remainder of the money to fund other projects. Our client was so satisfied by the work and the resulting savings that they sent EAD a thank you letter.
Our client’s PLC-5 processor technology was so outdated that it was no longer able to meet their needs. EAD was able to set up a block transfer to resolve the issue.
$12K allocated – Client only spent $9K due to EAD’s cost saving measures
- Work completed 1 week ahead of schedule
- EAD solution increased daily cereal production by 33,000 pounds over the client’s target
- Entire system brought online after only a few hours of testing because there were no programming errors