Production line automation
At EcoSurfaces
EcoSurfaces, a locally owned and operated business, specialises in providing safe and sustainable benchtop surfaces that are silica-free. Their mission is to create high-quality, environmentally friendly products for their clients. Eco Surfaces reached out to ControlX to help automate a part of the production line. The machineries included in the stone slab delayering production line are a calibrator, turntable and a surface polisher.
Challenges
Quality at a fair price
Meeting client expectations to deliver a high quality but affordable benchtops.
High labour cost
The imported machines from overseas require a few operators per machine to monitor the production quality.
Second-hand machines
The imported machines are second-hand and have limited documentation. The safety of the machines isn’t up to Australian standards.
Solution
Automated production line
Every machine on the line was automated with a PLC control system and additional sensors, to cut the manual labour in production. The operator screen runs on a tablet, so the operator can control and monitor the line while walking around the machines.
Centralised control
One control system for the whole line gives real-time monitoring and control of every machine, to lift quality and efficiency. From that data, adjustments are made automatically or from the operator screens.
Updated control panels
A production and risk assessment set the level of upgrade for each machine’s electrical system. Every machine got schematics and documentation for maintenance and fault finding, and the control system can be reached remotely for quick support.
Results
27% fewer errors
Automated systems minimise defects, ensuring more consistent high-quality products. Most manual steps were automated to reduce operator’s interaction. The automated modes maintain constant monitoring of the machine conditions. Main production steps like the shift start, tooling, production starts and stops are automatically captured.
25% lower labour cost
By automating repetitive tasks, EcoSurfaces removed a need for manual labour and operator’s interaction, leading to cost savings. Machines that originally required 2-3 people to operate now only require one person to monitor the whole production process. Most of the production runs in automatic mode and requires only passive supervision.
New control system
New control system has the latest technologies in controls and operator interactions. User Interface is intuitive and tailored to the specific process. New electrical panels designed to Australian standards with associated safety requirements. This aiming to increase the production output.
Client testimonial
Rhys Bennett, General Manager
ControlX has provided outstanding support for our automation needs at Eco Surfaces Australia. Their expertise and system integration have allowed us to streamline our production process, improving both efficiency and output. With their solutions, we are now confidently producing up to 7 slabs per day. Their team has been professional, responsive, and highly skilled, making them a key partner in enhancing our manufacturing capabilities.
We recommend ControlX.