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Fontana Luigi Spa

Fontana Luigi Spa

Revamping automated warehouse, New WIP Software Application and Overhead Crane Revamping

Solutions

Automated Warehouse

Material Handling and Sorting

Robotics

software

revamping

Sector

Metallurgical

Challenge

(2014) The main need was the technological modernization of a very old plant for which neither mechanical spare parts nor, above all, electronic ones were available anymore. As with almost all revamping projects, the time available for modification activities was extremely limited because the warehouse was essential for production processes.

(2015) The production progress monitoring towards the departments was essential to improve production efficiency levels. At the same time, it was necessary to carry out the technological renewal of some plants, particularly the crane in the pickling department, which operated manually with a man on board, to make it automatic.

Solution

(2014) Design and implementation of technological renewal with a step-by-step approach and micro-stops for testing individual subsystems to minimize production downtime. Interventions carried out. (2015) In 2015, LCS carried out two distinct projects in parallel.

(2014)

  • Electromechanical Part: Modernization of all machines with the replacement of motors, on-board machine electrical components, electrical panels, and control PLCs. Simultaneously, modifications were made to the picking area.
  • Safety: Upgrade of all plant safety measures.
  • PLC Software Part: Development of PLC software according to LCS standards.
  • PC Software Part: Development of WMS and WCS software for plant management and control, with the implementation of new functionalities.
  • Service: Taking over the plant with continuous maintenance by LCS.

 

(2015)

Work in Progress: A newly developed software application integrated with the WMS.

  • The application allows for monitoring the production progress of each machine in the department and tracking the consumption of materials.
  • The integration with the WMS enabled the first level of automation for creating handling orders from the Warehouse to Production.

 

Revamping of the Pickling Crane:

  • The plant underwent technological renewal with the replacement of the electromechanical part (gear motors, on-board machine components, electrical panels, and special components) and the complete redevelopment of the software.
  • Necessary modifications were made to transition from the original manual operation with “man on board” to fully automatic mode.
  • New CE certification of the plant.

Key technical data

(2014)

  • Warehouse with internal shelving for Eur pallets
  • N.3 single-depth stacker cranes with transfer bridge
  • N.1 two-level conveyor system controlled by N.2 PLCs
  • WMS interconnected with company ERP and departmental production software

 

(2015)

  • Activation of 24/7 Assistance and Maintenance Services

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