Painted Body Storage Overhaul

We were approached by an existing customer to develop a solution to an issue they were having that was causing extended downtime and a reoccurring basis.  Our customer had a storage bank between the Paint Department and Final Assembly that was controlled by an IBM OS/2 based workstation/PC.  The OS/2 workstation/PC contained the data that determined which vehicle bodies were released to Final Assembly.

The issue that the customer had was that at least once a quarter there would be an issue with the data being corrupted.  These data issues would require manual intervention and result in an extended amount of downtime, and a loss in productivity, until the data issue was sorted out.  

We, at PCS, used our experience as a certified Mitsubishi integrator (we are also a participant in the Mitsubishi System Integrator Program (MESIP)) to develop a solution that used the Mitsubishi Q-series PLC and P+F RFID tags to track the actual carriers and their contents.  This created a redundant system to track the carrier data and eliminated data errors.   

Our experience as a Cognex Vision Systems Certified System Integrator (CSI) also allowed us to introduce a vision system that removed human intervention, human error, and allowed for automatic carrier routing.  

This implementation by our experienced engineers dramatically reduced system downtime by creating a robust system that eliminated hardware failures and reduced human intervention.   

The highlights of the system included:

  • Mitsubishi Q-Series Processor
  • Mitsubishi GOT1000
  • Mitsubishi SoftGOT
  • 2D Data Marking
  • Cognex In-Sight 5400 Camera
  • Pepperl+Fuchs (P+F) RFI Tag System
  • Mitsubishi MelSecNet/10 communications
  • Ethernet communications
  • Rockwell FactoryTalk View SE

Tank Farm Control System

A global automotive manufacturer required a turn-key hardware and software controls solution for an automated system to monitor the ventilation and provide safety functions in a fluid-fill (non-gasoline) environment to ensure a safe environment for...

Gate Release System Design and Implementation

Our long-standing customer had an issue where production vehicles that were not ready for release to shipping, due to quality concerns, were being shipped.  In order to correct this issue and improve quality, our customer requested our...

Tire and Wheel System PLC Upgrade

Due to the march of time, our customer found that the material support for an existing Tire and Wheel System that was built around the Allen-Bradley PLC-5 platform was becoming an issue.  In order to maintain their manufacturing commitments, it...

Controls Training

We recently had a new customer request training for their technicians on reading electrical schematics so they could wire their own machines and control panels instead of outsourcing.  This required a custom approach that would apply...

Mitsubishi PLC Training

Just finished working with a customer that was awarded a new project requiring Mitsubishi PLCs, but they never integrated one before.  After just a few days of Custom Mitsubishi Training, we got them up and running with a MELSEC-QS Safety PLC,...

MEL-FACS Certification

In addition to being a Mitsubishi Certified Integrator, we're also Mitsubishi MEL-FACS Certified.  Hire a specialist that works with it full-time; we’re much more efficient.  By using an Integrator that...

Mitsubishi System Integrators

System integrators are important resources that are found in factories all across the nation. Whether you’re involved with equipment building, or you’re the beneficiary of the end result, system integrators can be an invaluable aspect of...

Cognex Certified System Integrator

PCS successfully integrated multiple Cognex In-Sight Vision Systems to an existing system for a long-time customer recently.  We were the Vision Integrator of the original system in 2006, along with additions in 2013; so we...

Keyence MD-F3120 Laser Marker and SR-D100 Reader

PCS was recently called upon to integrate a Keyence MD-F3120 Laser Marker and SR-D100 Reader into a Material Handling System for a Global Automotive Manufacturer.  The customer requested a very robust solution for their part-tracking...

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