Projects

Procontrol Systems has worked on a large number of projects in all manner of industries including:

Listed below are some of our clients and completed projects.

Safety Medical Products

Safety Medical Products (Safetymed) is a pharmaceutical company with an emphasis on safety of medical equipment. As of early 2007 Safetymed fully owns Procontrol Systems.

Safety Medical Securetouch Safety Syringe Assembly Machine (2006-2007)

Click on the above link for more information.

General Motors Holden (1983-present)

GMH has been a client for many years and we proven ourselves working in a high pressure continuous production environment.

White Body/Painted Body Storage Facility (1996)

This project involved the storage and sorting of unpainted and painted car bodies ready for distribution to New Enamel Paint Shop or Final Assembly workshops. It included a monorail type conveyor consisting of 15 storage lanes, a recirculation lane, white body entry and exist zones, 4 body transfer lifts, painted entry and exist zones, 5 body transfer lifts, empty carrier return zones and carrier maintenance spur zones.

P-Line Mezzanine Conveyor (2004)

A new overhead Mezzanine Accumulating Conveyor including a new Lift Tower, Drop Tower and Turntable all synchronised into the existing Body Shop floor conveyors. These are all controlled by an Allen Bradley Control Logix PLC with multiple VSDs, Touchscreens and associated safety systems.

NEPS Colour Changer Project (2004)

The design and development of a colour tracking system throughout the NEPS facility to ensure the correct paint colour is applied to the correct body.

Continual Engineering Projects

Various Transfer points requiring model detection and correct precise positioning on tooling using various methods of laser sensing. Various programming and logistical debugging projects throughout the Holden plants, mainly on Siemens, Allen Bradley PLCs and Touch Screens.

Amcor

Amcor Glass is the largest glass bottle manufacturer in SA. They produce an average of 1 million bottles per day.

Commissioning of Warehouse Overhead Conveyor (2006)

A new overhead conveyor system transports bottles stacked on pallets 100 metres across a warehouse on two conveyor lines. Extensive PLC and HMI improvements were engineered to ensure the reliability of the system and minimise downtime.

NKC Conveyors

Many projects have been completed with the collaboration between NKC and Procontrol Systems.

Sealer Buffer Project (2002)

The complete design, installation and commissioning of a high speed shuttle line with 6 stop stations interfaced with spraying robots for sealer to car bodies. Multiple safety and warning systems were integrated to the shuttle line and travel conveyors. The synchronisation of the delivery conveyor was achieved using Siemens VSD drives and PLCs.

Futuris (formerly Air International)

Futuris supply seats, Heating Venting and Cooling systems (HVAC) and carpeting to GMH in Adelaide.

Assembly Line Traceability System (2005)

A data management system was developed to provide access to assembly data for every product built, and to log safety critical torque data and test results to a central database. In addition, a SCADA network consisting of nine HMI stations was installed for operators to view and update QA data, and to step operators through build/test procedures. The development of a web interface provided restricted access for managers and engineers to information stored on the central database.

Safety Critical Part Verification Vision System (2006)

Utilising the latest vision products and methodologies, a test machine was developed for the purposes of verifying correct operator assembly of a safety critical product. The vision system had to tolerate a large range of product variation and still provide a failproof pass.

Dayco

V-Fold Belt Filter Press (ongoing)

This involves the design, installation and commissioning of fully automatic control systems for numerous Belt Filter Presses. The presses must comply with standards world wide, Incorporating PLCs, Touchscreens and level/flow sensing.

National Foods

Remote Temperature Monitoring (2004)

For the design and installation of control panels for the ability to have remote temperature monitoring of Cool Rooms back at the head office in Salisbury. These were installed on National Foods sites at Pt Pirie and Pt Augusta.

AI Automotive

Iron Hand Project (2002)

For the design, installation and commissioning of a fully operational Iron Hand attached and interfaced to a 75 Tonne Press line for removing large components. Clearly this involved numerous safety issues and required compliance with the relevant safety standards.

Cutler Brands

Bottle Decorating Line (2002)

This project involved the design, installation and commissioning of a fully automated bottle printing line. Project work included a design of a destacker, interfacing to a print machine and Lehr oven, a repalletiser and finally a shrink wrapper. There were additional electrical upgrades and improvements to other existing machinery and processes including Touchscreens and PLC systems.

Mayne Pharma

Engineering Support (2005-2006)

Priority support was provided for a product coating system. On-going improvements were also undertaken on the complex process control system.

Johnson Controls

Johnson Controls is a global manufacturer of interior automotive parts. Their manufacturing facility in Adelaide builds interior doors and headliners for VE and WM Holden vehicles.

Engineering Support (2006)

The contract invloved a major re-programming exercise of all PLC and Touchscreen systems, to ensure both the door and headliner assembly lines were operational before their launch date. The main focus of this work was to ensure ongoing machine reliability, maintain a high quality of finished product and to minimise cycle times in an attempt to maintain strict production rates.

After product launch, Procontrol Systems provided full-time on-site engineering support for an additional three months to investigate and implement continuous improvement strategies to assist in improving the overall performance of each production line. This included the introduction of additional hardwired quality checks, system process improvements and operator interface standardisation.

Bluetooth Quality Check (2006)

This involved the design, manufacture and programming of a device to test the operation of Bluetooth microphones installed in Holden headliner consoles. This test was then integrated into the existing harness test.