Reduction in downtime and improved Comms using

“Interface Manager”

Improved system performance for Web retailer –

A leading online retailer, with a successful, well established  business has benefitted from the implementation of an ”Interface Manager” software solution. Due to the success of the business which lead to significant increases in volume at its logistics Centre it needed to upgrade part of the conveyor control  system and host interfacing.

The existing system, installed some years ago was based around two PLCs, one which looked after motor control and switching and the other looked after sortation, code reading and comms with host.

As volumes increased and comms traffic got greater the need arose to upgrade the processing on the system. Some processes were now causing the system to react much slower than was needed and could have resulted in errors. The client was keen to ensure that they had full messaging control and could easily configure the system to incorporate any future management information  that might be required. The various possibilities were discussed and tit was concluded that a single super fast PLC was required with the “Gateway” to host via a unique PC based software package “Interface Manager”.

“Interface Manager”. is a modular communications product which enables several different types of system to communicate.
The product is a collection of software modules which can be adpated for each individual application. Each module is able to communicate with any other module and an external system, allowing many different configuration combinations.

Typical modules include:

• Rockwell PLC communications
• Siemens PLC communications
• OPC
• TCP/IP communications
• LSI communications
• BCC Communication
• COMLI Communications
• DUST 3964R Communications
• Serial communication
• XML communication
• Project-specific modules can also be supplied

This gives a very flexible and very cost effective 'off the shelf' solution for device communications and protocol conversions.

A typical application would be like this one where a part of a system has been upgraded ie the PLC upgrade. “Interface Manager”. can be used to enable communications between the new PLC system and the existing host system, without having to change the existing host software.

In this instance the PLC was upgraded from the Rockwell SLC range to the Contrologix range, The “Interface Manager”. system was loaded to the PC and a careful switch over was implemented. Lots of testing both on and off site gave the client the confidence that this could achieve significant increases in performance.

Following the successful transition the client reported huge benefits very early on and said that the payback was less than 6 months due to the increased throughput and reduced downtime due to comms issues. The client also reported that they were able to reduce headcount as the need for checking/supervision was reduced.

Improved packing efficiency with;

Packing automation

Integrated solution for Web retailer –

Leading web retailer benefits from a packing automation solution which incorporates, carton erection, auto labeling and auto carton completion.

A small system can reap huge rewards and in this instance the relatively small amount of powered conveyor did just that. The key to the project was the integration of all elements from suppliers and partners such as Logopack, B+ and Macfarlane packaging.

The system enables the customer to concentrate on what they are good at rather than worrying about the pack operation. The packing is now concentrated into two lines, handling two different footprint cartons. The order details are coordinated using “Interface Manager” and the packs are reconciled with ship details ready for auto labeling.

Benefits:

• The pack errors are reduced as the data is automatically obtained, scanned and reconciled.
• Pack sizes have been optimized so that products can suit either of the two footprints, - reduced consumable costs and stock holding.
• The specialized pack machinery enables the carton to be formed to the product size  - avoiding the need for Void Fill and reducing costs and packing effort.
•  Management statistics are produced in varied report formats.
• Pick/Pack waves can be selected on demand, enabling super fast turnaround.
•  The Web based “Interface manager” Solution means that data can be viewed from any location.