Customer Success: Pharmaceutical Cleanroom Standardization

What if you could dramatically reduce manufacturing costs, accelerate production cycles, and enhance the reliability of your control systems?

What if you could dramatically reduce manufacturing costs, accelerate production cycles, and enhance the reliability of your control systems?

75% reduction in component costs
80% decrease in programming time
30% smaller control panel footprint

Curious how they optimized their control systems?

“I’ve worked with a lot of companies that provide solutions around Automation and Controls across Texas and the Gulf Coast over my 30 years in this line of work, including time with one o the biggest oil majors, and AWC tops them all.”

Optimizing older control system designs or developing new systems requires a structured approach that utilizes the latest technology and expert resources.

What does AWC, Inc. suggest for PLC system needs analysis?

Since 1965, AWC, Inc. has helped engineering managers recognize automation efficiency by following our structured approach. It begins with a thorough needs analysis process that includes evaluating the current system, defining customer resource plans, identifying problems and goals, outlining restrictions, defining solution attributes, and assessing change risks.

Let’s see if we can help.

Chat with Our Team Today

AWC’s Control System Optimization Process

  • 1 Needs Analysis
  • 2 Identify Options
  • 3 Review Alternatives
  • 4 Design Solution
  • 5 Customer Review & Feedback
  • 6 Sourcing & Division of Labor
  • 7 Proof of Concept
  • 8 Prototype
  • 9 Production

Chat with one of our Specialists to schedule a Control System Optimization Review.​

Step 1

Needs Analysis

We will schedule a 45-minute discussion of your current control system and general functional requirements. Along with your improvement goals, time, resource and budget restrictions.​

Current Situation (PLC Based Automation)​

  • NDA Requirements​
  • Timing
  • Number of systems​
  • Budget/System​​

As is

  • System Overview – What does the system do?
  • System Topology/Architecture (Drawing)
  • Customer resource plan: User requirements definition, Design, Build, Program, Commission, Support
  • Anticipated Scope of Work (AWC/ACE/A3IM)
Problems / Goals​
  • Reliability
  • Cost​
  • Size​
  • Communications/Remote Monitoring
  • Control Functionality
  • Scalability
  • Flexibility/Reusability​
  • Diagnostics​
  • Support​
  • Spare parts availability/cost​
  • Safety​
  • Security​
  • Operator Experience (ease of use)
  • Other
Implications?​​
  • What is the urgency, impacts of no change?
Restrictions?​
  • List technology or resource constraints​​
Need Definition?​
  • Summarize the solution attributes (not the solution) needed to meet their goals/requirements
Change Risk? (Escalate for approval to proceed)​
  • ​​Health, Safety, Environmental (PSM)
  • ​​​Loss of Production​
  • ​​Material Loss​
  • ​​Legal
Step 2

Identify Options

If it sounds like we can help you achieve your goals, our Automation Engineering team will conduct a review of your current control system or system specifications.​​

The review will include an order of magnitude estimate to determine if the desired functionality can be met within your schedule and budget goals.​

Documentation​
  • P&IDs​
  • Schematics
  • Sequence of Operations, C&E​​
  • Existing programs, etc.​
  • ​Tag List​​​

I/O Count & Type​
  • Local ​​​
  • Remote Drops​​​ ​​​
Panel Considerations​
  • Heat load calculation​​​​
  • Minimum spacing​
  • Heating/Cooling – HVAC, Fan, Heaters

System Architecture​​
  • PLCs, RTUs, Single Board Controller,
  • ​HMIs​
  • Network hardware​
  • DCS, SCADA​
  • On premises/Cloud Gateways​
  • Data export/Analysis
  • VFDs
  • ​DC Power/UPSs​
  • CBs, Fuses, Disconnects
  • Motor starters,
  • VFDs

I/O Count & Type​

  • Local ​​​
  • Remote Drops​​​ ​​​
Power Requirements​
  • Incoming Power Feed: 480V, 230V, 120V​
  • Transformer, Generator, UPS/Battery, Solar
  • Grounding/Bonding/Surge Suppression​
  • Field Power​
Environmental​
  • NEMA rating​​
  • Corrosion Protection: Stainless Steel, Carbon Steel, Aluminum, Plastic​​
  • Hazardous Area Ratings/Intrinsic Safety​
  • ​Unique Certifications/Approvals​
Step 3

Review Alternatives

If our analysis proves we can help, we will provide a Preliminary System Design and Budget for your consideration at no charge. If you decide to proceed, we will work with your team to complete the process and deliver an optimized system that meets your goals. See how our team can help streamline your operations. Get started with a personalized evaluation.

Legacy automation holding you back? Discover how AWC approaches the challenge.

An Original Equipment Manufacturer of chemical injection skids needed to remotely monitor their equipment health to ensure ZERO down time for their customers. Their legacy automation platform supplier “nickeled and dimed” them to the point of making the equipment too expensive.

In addition to the excessive costs for remote monitoring, the legacy system also required two controllers with two different software platforms making control system updates painful.

To provide the OEM with the remote monitoring capabilities and cost reductions they needed, AWC followed a clear and effective process. Together we were able to help them realize some amazing results, including:

  • Material Cost savings of $30,000/skid (over $570,000/year)
  • Reduced number of components (Integrated Ethernet switch, gateway)
  • Reduce project engineering and support time by over 40 hours/skid

This involved these key stages:

1 Needs Analyzed & Communicated​
  • Reduce downtime with more accurate and frequent data collection
    • Injection skid pressure, flow, temperature, and tank levels
  • Increase injection measurement and control
  • Reduce time required for design improvements ​
  • ​Simplify field support​​​
2 Project Scope Defined​
  • PLC Panel
  • Power Distribution Panel
  • MOV (Motor Operated Valve)
  • Pressure, Temperature, and flow Transmitters
  • NEMA Motors
  • C1D2 LED lighting
3 Solution Presented
  • Analysis of existing system
  • Engineering design and software development support
  • Project management
  • Initial proof of concept and prototype build
  • Testing and Commissioning
  • Local Inventory and kitting services (Multiple system builds)
Talk with our chat team about scheduling a Control System Optimization Review.
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