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This year I S Systems Pty Limited was nominated as finalists in the 7th Annual Pace Zenith Awards program for the following projects:

Category: Automotive & Manufacturing

Fairfax Newspapers, Chullora NSW
Reengineer LGV and Reel Stand Integration

FAIRFAX printers in Chullora Sydney were faced with a problem. Remote control vehicles (LGV) are guided around the print floor by lasers and shift extremely large rolls of newsprint to the printing machines, then load the heavy rolls automatically onto the unwind reel stands on the printing press. The system ensures that the press operates continously and does not run out of paper. At the heart of arrangement is a proprietary Kubus management system that controls the LGV call and printer reel stand loading.

The legacy control system was becoming increasingly unreliable (and uneconomic to maintain) and due to the complexity of the control software and communications, it was extremely difficult to perform small modifications that could lead to significant operational improvements. Fairfax needed to look at alternatives to the existing Kubus control system, as they felt that they were not only at risk in the longer term (as the system would no longer be supportable) but they were also constrained buy tht system's inflexibility.

Category: Metal Products

OneSteel Mill, Newcastle NSW
Schedule Updates and Production Tracker

The SCADA system at the OneSteel Waratah mill could not deliver the functionality that was required. OneSteel wished to implement a customised mill scheduling and tracking sytem of individual product lines to enhance their ability to perform quick changeovers and log and track the product. A key requirement was that a baseline set over 300 production parameters needed to be created and stored for each of the product lines at the plant. These settings include parameters relating to speed, temperature, tension and pressures over the entire manufacturing process.

A collaborative strategy was developed to create a series of baseline settings that would operate in the ideal world situation. These baseline settings were then used for the standard production setup. The existing method of storing the schedules in discreet files in the SCADA database format was replaced with a robust and open SQL server, and the SCADA project backend re-written to interace to this new database.

The new database not only removed the limitations and speed issues of the previous database, but allowed other programs to access the schedule data, which was taken full advantage of to create web based pages to interface to the database and allow editing and viewing of schedules from anywhere on the company intranet. The web based interface enables management to view the production records both historically and in real time from the company intranet, without disturbing or interfering with the operation of the mill.

(Source: May 2010 issue of Pacetoday)