PRODUCTION LINE automation

Achieving High

Quality Benchtops

Meeting client expectations to deliver a high quality but affordable benchtops.

High Labour

Cost

The imported machines from overseas require a few operators per machine to monitor the production quality.

Second-hand

Machines

The imported machines are second hand and have limited documentation. The safety of the machines isn’t up to Australian standards.

Automated Production Line

An automated production line was implemented to minimise human labour in the manufacturing process.

All machines and their components were automated by introducing an advanced PLCs control system with additional sensors. The system HMI (Operators Interface) is installed on a Tablet PC for mobility. The operator is able to control and monitor the system while walking around the machinery.

Centralised Control System

A centralised control system using advanced protocols was implemented to increase overall quality and efficiency of the manufacturing process by providing real-time monitoring and control of the entire production line. Using this data, adjustments and improvement can be implemented automatically or via HMI displays.

Updated Control Panels 

Production and risk assessment were conducted to design a tailored electrical system with the level of needed upgrade. Electrical schematics and documentation were developed for each machine to rescue time for machine maintenance and possible troubleshooting. The control system was equipped with a modern PLC’s and an advanced computerised system. The system can be accessed remotely for prompt troubleshooting and assistance.

Automated systems minimise defects, ensuring more consistent high-quality products. Most manual steps were automated to reduce operator’s interaction. The automated modes maintain constant monitoring of the machine conditions. Main production steps like the shift start, tooling, production starts and stops are automatically captured.

By automating repetitive tasks, EcoSurfaces removed a need for manual labour and operator’s interaction, leading to cost savings. Machines that originally required 2-3 people to operate now only require one person to monitor the whole production process. Most of the production runs in automatic mode and requires only passive supervision.

New control system has the latest technologies in controls and operator interactions. User Interface is intuitive and tailored to the specific process. New electrical panels designed to Australian standards with associated safety requirements. This aiming to increase the production output.