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Sticky Situation
The H.B. Fuller Construction Products division, headquartered in Aurora, IL, is at the forefront of construction products innovation. Here, a very lean crew formulates, mixes and packages a long list of mastics, coatings, sealants and adhesives used in commercial and residential construction.
They make ceramic tile installation products, flooring adhesives, surface preparation products, exterior insulation finish systems and epoxy flooring for commercial and professional contractor markets. They also batch pre-mixed grouts, mortars and other products targeted predominantly to the retail home improvement marketplace. Jim Holman, president of Fox Valley Scale, New Lenox, IL, puts it in a nutshell, “They make sticky stuff.” Fox Valley Scale was called to the H. B. Fuller Construction Products plant to come up with a solution for what could have been a sticky situation.
Geoffrey Russell, production manager, and Jim Sansone, maintenance manager, recall the day they were advised that a variety of new processing and packaging equipment was being moved to the Aurora facility. Jim remembers, “We had to figure out how we could combine that new production equipment with the existing manufacturing area and be up and running in ninety days.”
Jim Sansone, maintenance manager, reviewed current production methods of the used equipment transferring to the Aurora factory. He realized that much of the equipment and processes were well over 20 years old and needed an upgrade in technology. Manual raw material weighing systems needed to be automated. The company had limited knowledge in using load cells and wanted to minimize capital spent on the relocation of the equipment. Jim notes, “We had to justify the money.”
Jim Holman did his research and Fox Valley Scale came back with this 920i® solution. Holman remembers the planning meeting. “I came up to Rice Lake and had a breakfast meeting with Don Fiedler and Marvin Stodola [Rice Lake engineers] and Mike Ryan [Rice Lake Great Lakes regional director]. We literally figured it out in an hour on the back of a napkin at the restaurant. Kristi Gay [Rice Lake engineer] wrote the program and created the tables to recall formulas.”
The system includes eight 920is with 24-channel I/O and Ethernet® outputs. Holman believes the solution is perfect. “All the 920is are tied to one network printer. Supervisors are using Interchange® to load formulas from the office via the printer. One really neat aspect of the system is that any one of the 920is can be used as a backup for any of the others. The I/O is redundant throughout the system. It can be changed simply wire for wire.”
Meanwhile, back at the plant in Aurora, Sansone and Russell were designing and building the steel mezzanine.
Sansone recalls the Big Day. “The first time we fired it up, everything worked!
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