AMS Controls takes great pride in supplying integration solutions that support its customer’s productivity and profitability goals. At the end of every project, the measure of success for AMS is to no longer be thought of as a supplier but to be considered a business partner.
AMS designs and manufactures the finest lineup of machine controllers and most technically advanced integration software available. The ability to incorporate these into current equipment and leverage three decades of industry experience to help achieve customer’s goals puts AMS in a very unique position.
Recently, AMS Controls engaged in a project to integrate several manufacturing lines for Nucor Building Systems. Nucor is one of the most respected steel companies in the world.
The catalyst for Nucor to select AMS to supply equipment and technology was the need for seamless integration of new equipment with existing equipment and infrastructure, all in a way that provided quick return on investment and minimal disruption to operations.
Four years ago, we changed the way we bundle roof panels.We started doing a staggered end lap which made it very intensive for the operator to enter orders by hand at the controller. IT proposed automation could make our operator’s more efficient and reduce the risk of error.
By improving on this system, Nucor estimated they could save “several hours a week,” in data entry at each machine by automating the part download. They approached AMS to help make this happen.
The potential for even greater benefits working with an experienced partner such as AMS became evident quickly. The full range of operational efficiencies that can be incorporated with AMS’ controllers and integration management software is extensive:
We discovered that we were able to do a lot more than just download cut-lists to our controller.We quickly latched onto features such as the ability to track down time, the ability to track scrap, material verification, real time monitoring of the line, snapshots of production, and the ability to use the same controller on all our different roll forming lines.This allows us to have one spare controller on site which can be used on any of our lines.
We typically say that a project has to have payback in 24 months or less before we commit to capital investment. Our justification was that we would save a minimum of 200 man hours in 2 years due to data entry. These 200 hours could then be turned in to additional production time which gave us additional income and reduced our cost.
Nucor has since integrated other tasks using AMS’ Eclipse management software including barcode scanning: This has reduced production loading to “just 15 minutes a week” per operator which has also served to increase accuracy and efficiency;
By downloading the parts we reduce the likely hood of a typo causing a bad part. We are also in process of integrating our coil inventory in to Eclipse which will allow us to do material verification i.e. the right size and color material for the job. All of this data is being automatically downloaded to the controllers. Our operators require little to no knowledge of how the jobs or coil data get to the controller.
The early success of the AMS installation led to the subsequent selection of AMS to integrate a purlin manufacturing line. Nucor was unable to load more than a couple days worth of production data. They were experiencing excessive scrap due to machine controller crashes and new coil loading, there were long lead times on replacement parts if something broke down, and there was inadequate documentation and reference material for the antiquated control system. A control system malfunction alone could have cost days if not weeks of valuable production time in troubleshooting, finding replacement parts, and installation time.
AMS met with Nucor management and listened to the goals that would accompany a controller and integration package. Of course, increased efficiency and a reduction in waste/scrap were identified as prime directives. But through the collaboration, AMS was able to support other goals:
- Better technical support.
- Replace critical components with parts stocked locally.
- Remove the need to reference all machine axes (this cost 15 minutes every time the profile was switched).
- Documentation for the system so the Nucor maintenance department could provide better long term support of the line.
- Part downloads across the network.
Purlin Line Retrofit Details
The old control system on the machine consisted of older style servo drives that are no longer supported, stepper motors and amplifiers which are not readily available to US customers, and control software which was written by a single European based programmer.
The existing programming added another level of complexity to the system. Setting up the roll forming tools for a particular profile and setting up the punch tooling for each target was managed through tables in a computer program – some of which uses DOS.
If any of the components in the old system or the software programs fail, it could have been disastrous to production deadlines and to the maintenance department. Ordering replacement parts for this system could involve long lead times and extra shipping cost, assuming Nucor found the parts in the first place.
The AMS replacement system offered many advantages over the older control technology. Each of the control consoles utilizes a touch screen HMI for line control. The screens are easy to maneuver through and they are organized according to function.
The AMS XL212CL controller is the main operator interface and it provides a path for communications to the Eclipse production management software. This allows for downloading of orders, punch patterns and auto setup of roll forming tooling.
AMS provided Nucor with a turnkey retrofit system. The system included new operator panels, machine controls, and 33 axes of servo equipment. AMS was able to integrate with the older style servo system on the roll-feed, so it was not replaced. This servo system could be upgraded in the future to reduce scrap further and improve overall operation of the line.
There were several on-site visits from the technical staff during the design phase of the project. Prior to the retrofit, the primary machine operator spent several days at the AMS facility looking at the new control panels and going through procedures for fine tuning.
Final functionality included:
- Immediate phone support.
- Siemens servo motors and components stocked locally.
- Knowledge transfer during retrofit to help the maintenance department troubleshoot the new controls and components of the line.
- Computerized scrap tracking.
- Increased operator efficiency.
- The new controller allows for downloading of information and can hold weeks of parts.
- Nucor can now shut off the machine anytime and not loose part data.
- Barcodes are used to load jobs, coils, delay codes etc. reducing the amount of typing the operator has to perform and increasing accuracy.
- Machine setup is much faster due to absolute encoders on the servo motors.
The system featured HMI’s at both ends of the machine for fine-tuning of the roll former or punch tooling positions as well as all other manual functions on the machine.
The AMS system warns the operator that a new profile is required to run the next part and that the roll former tooling must be changed. Once the operator approves the tooling change, the machine will setup automatically for the next profile.
The AMS system included absolute encoder feedback on all of the punch tooling positioning in the “Y” axis and for roll forming tool positioning. The absolute encoders eliminated the need for referencing and the high-performance servo motors greatly reduced the time needed to switch profiles.
The servo motors for the punch and roll tool adjustments were specified so that a single spare could be used in any position on the machine. The drives recognize the motors when they are connected and they will configure themselves according to the programmed parameters. The Siemens motors can be purchased locally and with a very short lead time.
Installation process
The installation was a very smooth process with AMS technicians spending two weeks on site. With the extensive nature of the installation, Nucor also took advantage of this downtime to perform other maintenance to their downed production lines.
Results of the Project
After two weeks of downtime, the Nucor machine returned to service. Nucor soon found that AMS was on target with the project and had exceeding objectives and return on investment goals. As discussed earlier there were two primary deliverables Nucor was looking for; scrap savings and efficiency gains.
We estimate that there has been a 33% scrap reduction. This is due to a combination of having a controller that does not crash and cause scrap and the ability to slow run material through our punch table. Slow run allows us to punch the first part while loading material.
Secondary gains were also realized in increased throughput and decreased downtime. “The AMS controller never crashes.” With the ability to focus on other bottlenecks created by more reliable and efficient controllers, Nucor has now been able to continue their drive toward operation efficiency.
Nucor identified during the installation process that supplier selection was also a key contributor to downtime reduction. By selecting a supplier such as AMS, replacement parts and service are available fast. Where previous lead time to get a problem line back up and running was difficult to measure, Nucor can now be certain they have a partner willing to do whatever it takes to get them running and keep them running.
Nucor’s Experience Working with AMS Controls
As mentioned, building a long term partnership with its customers is part of the AMS culture. Much attention to detail and follow up has resulted in an ongoing dialogue between AMS and Nucor to ensure Nucor’s objectives for controller and integration will always be met.
Rick Sears / Nucor: “AMS not only has a solid product but they are truly customer oriented. I think over the last four years I have talked to everyone from Andy Allman (AMS Controls President) to the field tech who retrofitted our lines. At every level of the AMS organization there is a key focus on making their customers more efficient and more profitable.”
Rick Sears / Nucor: “AMS has a top notch technical staff. They were able to retrieve all of our machine parameters and logic prior to the retrofit and modify them for the new controllers. In addition they have provided superb remote support on the rare occasions that we have had issues with our controllers.”
Please consider a consultation with AMS Controls, Inc. (info@amscontrols.com // 314-344-3144). The best time to install a retrofit controller package is during slow order periods so as to better manage the potential upswing in orders during busy times and keep those machines running.
Our sincere appreciation to Nucor and Mr. Rick Sears for their contributions to this article.