Case Study: X250 Assembly Machine Modifications Location: Magna Intier Automotive, Redditch

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 is 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 Muller. Finally the system was fully re-tested against an agreed site acceptance test specification and following comprehensive training of Muller’s operatives and technicians, the machines were put back into service.

Results: Mark Shone, Engineering Supervisor for the Warehouse and MHE at the Market