%I0.4 · Clients
Works in Ireland are performed on a contract basis through System Integrators — currently through Unity Automation. The projects delivered in Brazil between 2006 and 2022 were performed and managed by Glaison in his previous experience as founder of an industrial automation integration company, with a focus on CAPEX projects — the knowledge that today supports the consultancy services provided through Unity Automation. All the images below refer to these projects.
IE · Life Sciences — current chapter
Management of the utilities expansion project involving approximately 8,000 automation points; architecture based on Siemens SIMATIC S7-1500 integrated with Ignition SCADA, in accordance with the client's cybersecurity criteria.
ITOT Project Manager for a portfolio of CAPEX projects in Automation (Siemens PCS7, QBMS Desigo CC) and IT (QC Laboratories), with support for GMP Change Control approval.
Management of the implementation of Emerson's DeltaV Mobile for a new central alarm system (CAS), integrating DeltaV, Siemens and Rockwell databases via OPC (Kepware), with a 20% reduction in projected costs.
The company was responsible to a total investment of 1.2 million euros to adapt the safety of 152 machines (Safety Function) distributed throughout the manufacturing plant, certified to SIL 3 (Safety Integrity Level 3). About 1,920 safety automation devices were installed.
Implementation of a project to support the engine performance evaluation system (dynamometer) in partnership with a consulting company in southern Germany. The automation system, based on the Siemens Fail-safe 416F CPU, served as a reference for Bosch in the implementation of similar projects in the United States and Germany. FAT (Factory Acceptance Test) performed at the integrator’s premises and SAT (Site Acceptance Test) at the Bosch facilities in Brazil.
Responsible to an investment of around 1 million euros to adapt various safety-critical equipment — bending press machines, roll forming machines, thermoforming machines and extrusion machines. In these projects, around 1,530 safety automation devices were installed, and all control was performed by fail-safe CPUs (Siemens CPU 317F).
Responsible for managing the project to ensure the safety of a Continental production line (conveyor belt systems), audited by the Ministry of Labour due to the high risk it presented: two presses with 60 square metres each and around 650 high-tech safety devices installed in a single line. High-performance devices such as safety laser scanners, safety light curtains, hydraulic valve actuators in SIL 3 and fail-safe drives were necessary to reduce the high risks identified.
As this was the factory's largest production line, the commissioning strategy involved carrying out partial operations on Sundays over the course of a year in order to minimise the impact of a single shutdown. The OEE (Overall Equipment Effectiveness) calculation developed for the production lines showed the gain in productivity with the project due to the significant reduction in accidents.
Implementation of a SCADA (Siemens WinCC) across all equipment in the plant's substation to allow execution of energy demand studies (16,651 energy variables) through automatic reports of consumption by area, avoiding contracting energy at peak times. The project resulted in energy savings of almost half a million euros a year.
Development of a batch system to produce resin for the MDF industry, implemented in a DCS (Siemens PCS7) with a high-availability CPU (Siemens CPU 417H). Project managed the automation of the system responsible to all wood input in the MDF plant, totalling 13,545 automation points, with commissioning of the MCC (motor control centre), Siemens Simatic S7-400 PLCs and InTouch (Schneider AVEVA) SCADA.
Project managed all the process automation of the plant's utilities — supply of water, energy and sewage treatment — with 735 components being automated and development of the P&IDs for the integration of processes from different Vendors, as part of the company's Digital Manufacturing strategy.
Development of a process automation system, in partnership with a German company specialising in environmental control, allowing the operation and monitoring of the water treatment for the separation of chemical elements generated in the production process. The operation system allowed remote actions, avoiding contact of operators with chemical agents, and provides process information in automatic reports to meet the requirements of regulatory bodies concerning environmental standards — all stored and managed by the Historian embedded in the Elipse E3 SCADA.
Responsible for technological changes in the equipment and for its integration with the MES (SAP MII) to generate electronic records in compliance with GMP protocols. For this solution the supplied electrical panels were built in stainless steel and with IP69 protection degree due to the need of high-pressure washes for cleaning.
The plant produces enzymes to control and speed up reactions applied in the food and beverage industry, a main client being Unilever. The project was to develop process automation in accordance with the principles of GMP for the food industry, using Rockwell ControlLogix PLC and Rockwell Factory Talk SCADA systems.
Contract and fractional roles, on-site or remote — Ireland and Europe.
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