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  • Modernization of existing APCS systems

    Modernization of existing APCS systems

    Industrial equipment can last for decades, but its electronic components become obsolete much faster. Modernization of APCS is the most effective way to increase production profitability without capital expenditures on replacing machines or production lines.

    Key objectives addressed by modernization:

    ● Reduced downtime: Replacing worn components and switching to modern components minimizes the risk of sudden failures.

    ● Increased accuracy: New controllers and algorithms allow for more precise process tuning, reducing defect rates and raw material consumption.

    ● Informativeness: The implementation of modern diagnostic tools allows us to identify system bottlenecks even before an accident occurs.

    We conduct an audit of the current state of automation and offer a phased upgrade plan. This allows for the modernization of workshops without lengthy shutdowns of the main production line, maintaining the normal operating rhythm of the enterprise.

    Advantages of modernization

    – Real savings: you get the features of modern equipment at a price several times lower than a complete fleet replacement.

    – Transparency: instead of analog gauges and operator guesswork, you get clear graphs and reports on system operation in real time.

    – Reduced defects: modern algorithms eliminate errors due to human error or instability of old automation.

    FAQ

    Why invest in upgrading electronics if the mechanical components are still working?

    The main risk here is a sudden and prolonged shutdown. If a controller discontinued 15 years ago fails, you won't be able to buy it at the local store. You'll have to search for used parts or wait weeks for delivery while the plant is down. Modernization eliminates this weak link, transferring the system to a modern base that is easy to maintain and repair.

    Will the plant have to be completely shut down during the system redesign?

    This is the biggest fear of any manager, so we work in stages. The upgrade plan is designed so that the main work is carried out during scheduled maintenance windows or on weekends. In most cases, it is possible to replace the system piecemeal, maintaining the usual production schedule.

    Will the new sensors and controllers be compatible with the old machines?

    Yes, that's the whole point of engineering. We only replace the base and measuring instruments, adapting them to the existing drives and mechanisms. The new control system begins to recognize previously ignored nuances of the old machine's operation, which immediately impacts accuracy and raw material consumption.