The document discusses a control system for a customized metal finishing process. It describes various modules and controllers that make up the control network, including universal input/output modules, DCS controllers, and specialized controllers for pretreatment, wastewater treatment, air management, and more. It then outlines several areas where implementing process control can reduce costs, such as controlling chemical levels, mechanical variables, conveyors, ovens, parts tracking, and various painting processes.

1. Customized Metal Finishing Process Control Systems Call Bob Snaden at 989-627-7349 06/06/09

2. Flexible and Expandable Universal input / output modules Ethernet connectivity High Density Controller Universal 32 input / output cards Ethernet connectivity DCS Controllers 06/06/09

3. 06/06/09 File Server (SQL Database) Customer PCs Running VNC Engineering Workstation Air Management Controller Pre-Treatment Controller Lab Workstation WWT Controller and Touch-screen Customer Network Typical Control Network

4. Process Cost Reduction Areas Pretreatment Chemicals Washer Mechanics Conveyors Ovens Paint Application Waste Water Treatment 06/06/09

5. Pretreatment Washer Chemical Control Maintain accurate concentrations Correct additions based on bath contamination Chemical usage / inventory Alarm out of spec conditions 06/06/09

6. Chemical Control Cost Savings Less chemical use with more uniform addition rates Increase in properly cleaned and pretreated ware Recharging process tanks based on contamination levels 06/06/09

7. Pretreatment Washer Mechanical Variables Spray pressures Temperatures Tank levels Nozzle blockage Filter Condition 06/06/09

8. Mechanical Variables Cost Savings Improve quality due to consistent mechanical washer parameters Reduce fluctuations in concentration by accurate control of tank levels Reduce product defects when line stops with parts in washer Reduce low pressure conditions by indicating filters need cleaning 06/06/09

9. Conveyor Tracking Line Stoppages Line Speed Parts Counting Downtime reports 06/06/09

10. Conveyor Tracking Cost Savings Reduces lost production due to parts stopped in washer or ovens Reduces downtime for trolley and drive failures through monitoring Identify location of parts for accurate alarm notification 06/06/09

11. Oven Control Burner controls Stand-by mode Automatic start-up and/or shut-down Alarm temperatures by zone 06/06/09

12. Oven Control Cost Savings Minimizes over/under cured product Reduces gas consumption Reduces delays when start-up steps are not performed properly Aids maintenance personnel in troubleshooting problems 06/06/09

13. Parts Tracking Location/Quantity Determining number processed Washer conditions when parts are processed Turning on/off ovens when no parts are detected 06/06/09

14. Parts Tracking Source of cost savings Analysis of production Reduces rework Eliminates defects caused by line shut down Can be used to evaluate chemical and paint cost per unit processed Gas savings in ovens 06/06/09

15. Paint Application Controls Liquid Topcoat Line Powder Paint Line E-Coat paint 06/06/09

16. Liquid Paint Application Control paint temperatures Monitor paint supply pressures Monitor paint gun pressures Paint room air management 06/06/09

17. Powder Paint Application PowderTrak Patented paint usage tracking Humidity and Temperature control Paint booth maintenance scheduler 06/06/09

18. Electro-Coat Paint Application Monitor or control e-coat and permeate tanks Control paint additions 06/06/09

19. Electro-coat Paint Application Paint usage and environmental reporting Manual result entries 06/06/09

20. Process Water Controls Intelligent process control strategies based on: Pretreatment system overflows and tank dumps Chemical additions synchronized to flow-through rate Recirculate flows during alarm conditions Environmental reports: Flow rate totals pH Chemical Usage 06/06/09

21. Reports Material usage Chemical Paint Energy Source of cost savings: Data records material applied per, run, shift, day in true costs Data can be analyzed in SPC programs to show deviations from standard 06/06/09

22. Defect Reports Defect Tracking First pass yields Types of defects Alarm if abnormally high number of defects are recorded 06/06/09

23. Paint Thickness Reports Mil Thickness Readings automatically saved to controller 06/06/09

24. Alarm Notification Local alarm strobe Pager or cell phone text messaging E-mail to supervisor 06/06/09

25. Alarm Logging 06/06/09

26. Control System Project Cycle Engineering Control point list Wiring diagrams Operating sequences Installation Conduit and cable by customer Installation of devices and wiring of system Programming Custom control programs developed with customer input Training Customer training 06/06/09