Controlling process variables and minimizing operator dependency in the manufacturing process are two ways to maximize plant efficiency, improve product quality, and reduce costs associated with substandard products.

Genesys Controls Corporation was selected by a leading manufacturer to implement improvements to their manufacturing process. Their objective was to improve product quality. The high incidence of rejects and warranty returns that they were experiencing were negatively affecting their reputation, margins, and market share.

A critical element of their manufacturing process involved pneumatic presses. Successful production was dependent on both the pressure and duration of the pneumatic press operations. We developed a simple PLC-based system that automatically controlled these settings. Once it was implemented, pneumatic press related issues became a thing of the past. The PLC system also provided for production and reject data collection for cell performance on all of the different product varieties they manufacture, at a very minimal cost.