Project Description:
A global manufacturer of automotive axle assemblies was suffering with an outdated, difficult to use and maintain process control system. The existing system consisted of a centralized computer that tracked trays of parts as they traveled through the value added process. The central computer database was built on SQL Server with a proprietary front end. Changes required for process improvements were difficult and mainly accomplished by hiring the original equipment manufacturer at great expense. The customer was looking for a method of replacing the existing system so these changes could be made either by its own staff or a local resource. Additionally, the existing system “lost track” of some of the trays. Since automotive component manufacturers are bound by standards to provide genealogy to their customers, this was a problem waiting disaster.

Approach & Results:
Applied Sciences Group reverse-engineered the existing system and using COTS software produced a system that is now the benchmark for this customer. The system uses Rockwell Automation RSView32 as the front end computer and RSBizware Historian in a distributed architecture. A standard RSBizware Historian application is built upon templates supplied by Rockwell. Because of the complex tracking algorithms involved with the process, standard application methods could not be used and Applied Sciences Group had to modify the underlying SQL database that is the basis for Rockwell’s Historian. This and the distributed nature of the application pushed the envelope for the software, with the end result exceeding objectives for the customer. The upgrade was done in parallel to the existing system, so that validation could take place and a comfort level developed among operations personnel that the new system was indeed a more than adequate replacement for the existing system. The screens were mimicked virtually identical to the existing screens. Applied Sciences Group engineers took screen shots of the existing, and then duplicated the look and feel in every detail to make the acceptance by operations seamless. The human factors portion of the project was a critical component in its success. Loss of tray data is no longer an issue and by using off the shelf software components, the customer now has the ability to make changes to the system to support process improvement initiatives. Currently, Applied Sciences Group is installing the next of these systems at the customer facility in Mexico.