Plascon Paints, supplier of paint and related material to the industrial and commercial sectors and the retail market, has contracted CS Systems Integration, the manufacturing business unit of JSE-listed CS Holdings, to automate an existing paint filler at its Krugersdorp factory.
"The custom made paint filler is used for filling the paint cans at the Luipaardsvlei site," explains Richard Mackay, contract senior programmer at CS Systems Integration. "Plascon had previously contracted an Israeli company to do the automation of the fillers when the filling machines were first built. However, this system proved unsatisfactory for several reasons.
"Not only was it slow, but the control hardware was inadequate and the software was fraught with complications," he continues. "Additionally, because the system supplier was based in Israel, support was not forthcoming."
Consequently, Plascon approached System Solutions to assist it in its paint filler project. System Solutions had previously successfully implemented a batching application at Plascon, and had won an award in the Wonderware Open 2000 competition for the best application integration of the Wonderware suite of products for this project.
"We implemented and programmed a Premium PLC system from Schneider Electric," says Mackay. "Although not an imported product, the company is represented locally, so support is not a problem."
"The new filling system has proved to have some significant benefits for us," says Lafras Heron, engineering manager at Plascon. "It is far more accurate than any filling machine we have used in the past, and to our knowledge is also more accurate than most of the filling machines available on the international market.
"The speed of the filling machine is a little slower than we had hoped for, but it is adequate to achieve our throughput," he continues. "The consistency of the performance has meant that there are fewer stoppages and consequently, we are maintaining good throughputs. As the machine is accurate and reliable from the first container, the amount of spillages has reduced dramatically. Additionally, the filling machine is easy to set-up with a user-friendly operator interface to guide the set-up process."
Another major advantage of the new system is its transparency. "Previously, Plascon was unable to change any of the variables and parameters within the control system, owing to its overseas ownership," Mackay explains. "With the new system, however, they have access to all the parameters they need and can implement changes as their requirements change."
According to Heron, CS System Solutions has become Plascon`s preferred supplier, based on a relationship that spans a number of years. "They have proved themselves to be very competent in the field of PLC programming and system configuration, and we had every confidence that they would carry out a successful implementation," he concludes.
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CS Systems Integration, a division of JSE-listed CS Holdings, has four core business streams, providing applications requirements to achieve a truly integrated IT solution architecture. These are Strategy Solutions, Enterprise Management Systems, Production and Manufacturing Systems and Business Intelligence.
CS Systems Integration focuses on integrated applications and streamlined offerings to provide a complete solution across the full spectrum of the business and its supply chain.
This division enables a customer to link its IT strategy to its business strategy. CS Systems Integration can manage the synthesis and connectivity from top floor to shop floor, front office to back office systems in business, across the supply chain spectrum, inclusive of human resource, logistical, operational, and financial requirements. It will also optimise and integrate its clients` business systems and assist in the drive towards e-business.
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