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Cost and operational efficiency improvements

Chemicals

Fuchs Lubricants (UK) PLC

Stoke-on-Trent, Staffordshire United Kingdom

Fuchs Lubricants
Stoke-on-Trent, Staffordshire,
United Kingdom
With increasing demand for the company’s products driving production, the role of the legacy process control system was scrutinised. 
The decision was made to migrate from what was considered to be an increasingly vulnerable and obsolete system, and to specify Siemens’ PCS 7 with SIMATIC Batch DCS.
"We are achieving a significant first time pass rate for the finished products which has increased from 85% to 97%. This means a drop in failure rates to just 3% and that adds up to significantly lower levels of waste product having to be thrown away and substantial cost savings in terms of raw material consumption. In addition, our knowledge of the process is now far more in-depth, as the data we can extract from the control system informs us exactly of the type of key and highly accurate information we require to ensure product consistency and drive improvements to our efficiencies - such as around how we can reduce cycle times. This allows us to plan our production scheduling far more accurately, as well as driving flexibility.”
Steve Hallam, engineering manager for Fuchs
  • The enhanced performance of the system – including reduced plant downtime. 
  • The elimination of the potential for cross-contamination issues related to storage. Controls are in place to ensure the correct link between raw material intake, storage and blending tanks and finished product tanks at the end of the process and this control functionality has, for example, removed any instances of intake stock tank spills.
  • Higher plant availability and efficiency with the ability to remotely access the system from other locations via VPN dial-in, the engineering team can speedily analyse and respond to any issue and swiftly rectify problems before they hinder production.
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