Sure Controls

Plant Automation To Make You Sm;)e 1

We provide industrial process solutions with enthusiastic services & automation products that enable “World Class Manufacturing”

Plant Automation To Make You Sm;)e

About Us• Founded in 1984

• Privately Held

• Located in Greenville Wisconsin

• Global provider of products and Services

– Recent projects in Wales, France, and Mexico

– Products distributed in US, Canada, and Europe

Greenville

Our Mission: Delighting Our Customers With Design Foresight, Product Leadership And Unequaled Responsiveness

• Currently Occupy 18,000 Square Feet

• Thirty associates bringing over 200 years of experience and expertise to market

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Sure Associates

Sure Associates are dedicated to “Delighting Customers with Design Foresight, Product Leadership and Unequaled Responsiveness”.


Engineered control systems to :• increase safety • Improve product quality• Increase productivity• Reduce power consumption• Reduce down-time

Sure Controls designs, builds, installs and tests control systems to enhance safety, quality and productivity. Sure Controls’ project

management assures lower risk and excellent communications so you know project status exactly.

We understand your production processes so we can design solutions enabling you to meet your goals without over engineering.

EXAMPLES OF SURE CONTROLS INC. INTEGRATION PARTNERS

Sure Services Integration Solutions

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Designing new or rebuilding existing panels; our team of experts produce quality solutions that makes maintenance easier. We offer:• UL certification• CE compliance• Factory tested

Your design or ours, we take the time to assure the project makes ‘electrical sense’ at every turn while being reliable, compliant and easy to trouble shoot. Sure Controls can also take existing electrical schematics with redlines and produce clean new documentation reflecting the current state to minimize downtime.

Sure Services

Control Panel Design and Production

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Automated data collection and analysis (SCADA) allow you to make informed decisions that lower costs, improve quality and safety. Ask us how!

• Capture data reliably in real-time

• Access the data real-time

• Automate reporting saving analytical time

• View data and machine status locally at the machine, from your desk, or on the road from your mobile device.

• Plant floor visualization – key performance indicator and metric reporting

Sure Services

Plant Intelligence Solutions

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• Prompt friendly service for troubleshooting

• Preventive maintenance• Certified calibration services• 24/7 telephone access for

scheduling.

We call them enthusiastic services because our technicians understand the urgency and importance of increasing runtime and quality. Our goal is to return you to service as quickly as possible

We offer:24/7 telephone access for schedulingRemote troubleshooting services

Sure Services

Field Services

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Repair Services: Not sure

whether to repair or replace? Worried about how long it takes? Let Sure Controls experts assess your part. We’ll tell you if it costs less to replace than repair so you’ll know. Ask about our exchange program.

Training Services: Your

place or ours. Train on the same equipment you’re using hands on! Give your team more confidence and the ability to get you back into operation when problems arise

Sure Services

Training and Repair Services

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Electromechanical Example

• Pick and Place Gantry Style Robotic Integration System• Turn-Key

o Pick and place systemo End Effecter (gripper)o HMIo Mechanical support structure o Commissioning & Install

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Concept Completion


Example System Solution

• Parker provides mechanical sub-systems to

solve material handling applications including...

o Palletizing

o Storage and Retrieval

o Machine Loading

o Parts Transfer

o Automated Assembly


Safety

Achieve compliance with OSHA guarding and safe stopping regulations• Interlocked guarding switches, using guard safety relay• E-stop circuits updates with E-stop safety relay• Machine E-stop functionality: Fast stop, followed by power removal• Safety devices and circuitry at EN954 Class I safety standards


Safety

Applying design methods to meet ArcFlash requirements• Door mounted devices for ease of maintenance• Panels designed to meet SCCR needs• External disconnects achieving full power removal inside cabinet


Safety

Safety circuit updates

• Meets industry standards

• Capability of installation in hazardous locations

• Engineered quick stop, then motor power removal


Motion Control Example 1

Two axis conversion from hydraulic to AC motorso Increased production rates by nearly 2Xo Significantly reduced downtime associated with hydraulicso Improved process capability – can now process materials that

couldn’t be done in the past



Three axis web handling application DC to AC

o Eliminated obsolete drive equipment

o Improved processing capability

o Addressed ARCFlash needs

o Reduced motor PM requirements

Before After



Nine extruder drive conversion

o Eliminated obsolete drive equipment

o Improved processing capability

o Addressed ARCFlash needs


Motion Control - New Machine

New 15 axis machine – AC Motor Control

• Pre-installation verification

• ARCFlash ready

• Quick machine field commissioning


Motion Control - Servo

Supplied mechanical and electrical products and engineering to perform two axis injection control…

o High precision positioning

o Runs open or closed loop


Motion Control – Fan/Pump

Replaced existing across the line motor starter with V/Hz drive and closed loop with process feedback…

o Qualified for rebates from Focus on Energy

o 9 month payback on utility costs alone


Motion Control – Conveyors

Designed automation system for corrugator conveyor…

o UL Panels

o Auto/manual functionality

o Multiple stack configurations


Motion Control – Conveyors

Designed automation system for corrugator conveyor…

o Monitor barcodes on stacks

o Strap stacks according to size based on barcode


Other Motion Experience• Updated DC drives on:

o Web handling (unwind, rewind) extrusion line in Mexico

o 17 axis web handling line

o 26 axis web handling line

• Converted DC drive/motor to AC:o Multiple 200-300 HP extruders

o Material handling process equipment (paper, plastic, wire)


Machine Control – PLC

Upgraded Siemens S5 PLC to AB Control Logix• Ability to repeat functionality (requires understanding of both platforms)• Eliminated obsolete parts• Self-sufficient maintenance• Ability to move process/production data to network

Before After


Machine Control – PLC

PLC System Upgrade• Engineered/pre-wired in shop to meet minimum downtime

requirements• Assisted in field installation and commissioning providing 24

hour coverage


Process Control Upgrade

Upgraded obsolete MACO system to Eurotherm discrete w/comms

• Ease of maintenance

• Redundancy for operator setpoints

Before After



Upgrade temperature control using RKC SRZ system

• Low cost

• Ease of connectivity for process data mgmt

• Small form factor



Complete Drive, Temp, PLC and HMI upgrade of Sheet Line

Before After


Operator Interface

Update of a legacy system using the latest technology, yet able to maintain the ‘look and feel’ the operators were used to- thus minimizing impact of transition time.

Before After


Quality & MetricsThe Challenge:

To turn daily hand written run reports into real-time, accurate data measuring downtime and associated reasons for each occurrence.


Quality & Metrics

Using an operator interface coupled with machine I/O, barcode scanners and on-screen keyboard to collect the data…


Quality & Metrics

…We were able to bring rich web-based reports to the management team to help fuel their decisions.


Quality & Metrics

What did our customer get• $$$ - (12 month payback)

o Energy costs (estimated at $10K/mo)o Fewer operators (estimated at $100K/annually)o Fewer data entry clerks (estimated at $60K/annually)

• Increased Productivityo By developing goals for machines and specs and holding operators accountableo Able to respond to very accurate data concerning downtime and waste

• Visibilityo Easy access to the production data by all users over the Web


Putting Our Customer in Front

• Delivering a ‘superior experience’

• Single queue Customer Care email

• Tech Support team to help with obsolete or hard to find products

• 24/ 7 Telephone Response

• Experienced engineering to help you design your solution

• Field sales professionals

• Monthly customer satisfaction measurement– Web-based Survey every month

• WWW.SureControls.com– Information | Contact | Technical Information | Communication

http://www.surecontrols.com/


Our Commitment• We partner with you to solve challenges you

are currently facing.

• Our experts are available to:o Listen to your needs

o Design the right solutions

o Deliver turn-key integration that meets your requirements

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Documents

Sure Controls