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Müller - Case Study

Case Study: Müller, Pallet Checker System (Siemens S5/S7 PLC upgrade)

Project Description:  One of MCS Control Systems customers, Müller Dairy(UK) at Market Drayton, needed a specialist system integration contractor who could successfully replace obsolete business critical PLC’s in their multi-million pound production and automated warehouse operation, with minimum downtime and disruption.

Approach:  MCS Control Systems have a proven methodology, developed over the years for upgrading and replacing business critical PLC’s spanning many industry sectors including; food, fmcg, automotive, utilities, process and building services.  Karl Jordan, the MCS contracts manager on the project stated: “It’s all in the planning”, our approach is to validate the existing system, extract and convert the software, factory test/simulate and then transplant the PLC and HMI’s in a pre arranged and well planned shutdown.

At all stages, the key to success is to work with the client and understand their business, their risks and their people.  MCS’s progress was continuously monitored at all stages throughout the shutdowns against a detailed plan, this coupled with a robust contingency plan minimised any business risks to Müller.  Finally the system was fully re-tested against an agreed site acceptance test specification and following comprehensive training at Müller’s operatives and technicians, the machines were put back into service.

Results:  The engineering supervisor for the warehouse and MHE at the Market Drayton site, responsible for the project on behalf of Müller stated; “An exceptional, first-class service from MCS Control Systems with a thoroughly professional approach relating to all aspects of the project.  Extemporary cross-communications at all levels allowed for smooth integration of the new equipment with almost unnoticed disruption.  Including physical install, the machines were up and running again within a matter of hours – very impressive.”

 


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