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The ECS Solutions (ECS) team works on all manner of automation projects, from small to large and from very simple to highly complex.  Many of these projects have a major impact on the success of their clients but few are more satisfying than when a project’s results are a dramatic streamlining of plant operations tied in seamlessly with new or upgraded automation.

The most effective manufacturing companies enjoy a harmonious tie-in between the automation that exists, regardless of the level or magnitude, and the other systems that complete the plant operations.  Standardized procedures, reduced waste & increased quality, compliance with contracts and regulations, and better employee contribution are all hallmarks of the best manufacturers, and all lead to increased profits.

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Read More | Posted In: Case Studies, Food Industry, SCADA

A midwestern US chemical plant plays an integral part of the worldwide supply of stock for animal feed, refined human vegetable oils, and various other products. This family-owned operation has been a powerhouse in soybean processing, specifically, for more than half a century. As such, their processing areas for that product specifically are considered the epitome of “critical” and run year-round with only a single annual shutdown to handle most large-scale maintenance and upgrade projects.

As this plant looked to install the first ever automation to their critical extraction and shared cooler areas, they knew that this would be a large-scale project that would encompass a multitude of equipment and trades and that the installation would span several years.  This project would require partners who could handle the technical scope as well as the extended and complex project management.

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Read More | Posted In: Case Studies, Chemical Industry

Effective mass production manufacturing operations involve both monitoring of production processes and continual improvement.  ECS Solutions, Inc (ECS) has developed an innovative, powerful tool to help their clients develop peace of mind that their products are being manufactured accurately and efficiently while providing a platform to easily improve future interactions.  The Process DVR tool satisfies the modern expectation that anything that can be observed visually should be recorded and easily viewed later.  When used effectively, the result is truly optimized production control where the best-trained operators deliver accurate results with the least possible waste.

Data Historian capabilities have been built into many vendors’ SCADA systems for a long time.  Astute process engineers can call up trending information that illustrates the states and conditions within an automated system, the multitude of lines crisscrossing an HMI terminal in a way their trained eyes can discern.  This is an excellent tool by itself, provided that an operation has personnel who are trained to read and interpret the cryptic information that is returned from a standalone Historian.  ECS believed that this was conceptually sound but that a more manageable solution would help to bring wider benefits to their processing clients.

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Read More | Posted In: Bakery Industry, Beverage Industry, Chemical Industry, Clean in Place, Digitalization, Distilleries, Food Industry, Inductive Automation, Life Science Industry, SCADA

A key responsibility of executives and managers in manufacturing is that of risk management.  This refers to the obvious risk of physical operations and staff protection, but it also includes quite a bit more: risk to contracts, availability of brands of the direct employer and those of other clients, reputation(s), regulatory, and risk to public safety and health are all increasing concerns with the operating level of a senior executive or manager.

Risk identification is a critical first step; without which, corrective actions cannot be undertaken or could possibly be misguided.  Because risks evolve constantly, it is rare that they can be spelled out in a succinct and comprehensive volume. One obvious solution is to install the correct staff in the tiers immediately below the executives but that often raises questions about the specific qualifications of these employees, their tenure and familiarity with every facet of their role within that organization, and whether an overarching net has been cast to identify and compartmentalize relative risks.  Further concerns arise around whether an internal team is free of groupthink and whether they possess the proper experience, qualifications, and motivations. (more…)

Read More | Posted In: Bakery Industry, Beverage Industry, Chemical Industry, Food Industry, Life Science Industry, Metals Industry

Companies that operate in multi-step, multi-ingredient batch processing operations employ a combination of complex procedures, business and operational systems, and communications.  The range of tools and machinery used to process a potentially vast array of ingredients and process steps are what it takes to make processors successful.  Entire working cultures emerge from these operations that foster a focus and achieve positive outcomes.

The more specialized the market and operation, the lower number of people who operate within that domain. This doesn’t always allow for regular interaction with a broad spectrum of manufacturing peers, which can leave individuals and organizations feeling they are so unique that they are relatively isolated.  They frequently feel little confidence that people outside their close-knit internal group can effectively understand, let alone support them.  The possibility exists that they are rare, but they are not entirely unique and there are outside firms that are also closely aligned and, in fact, true peers as well.

ECS Solutions (ECS) operates upon this landscape. They have established a collective corporate consciousness that is aligned with the DNA of their core clients: batch processors.  ECS is immersed in the behaviors and characteristics of these clients, and it is reflected in nearly every aspect of their operation. (more…)

Read More | Posted In: Bakery Industry, Beverage Industry, Chemical Industry, Food Industry, Metals Industry, News

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