FEST GmbH modernized the automation and control technology of a more than 20-year-old slitting and cut-to-length line for KME Mansfeld GmbH. The plant had originally been set up by several different system houses, which led to a complex and in parts contradictory control architecture. The basis of the project was therefore a detailed analysis of the existing system in order to fully record the functions and transfer them to a modern, robust control structure.

The following measures were implemented as part of the conversion:

• Replacement of three Siemens S5 systems, a Siemens Simadyn controller and an Allen Bradley Reliance controller
• Construction of a new automation architecture based on two Siemens S7-1500 CPUs – separated into control and regulation units
• Introduction of an up-to-date visualization solution by migrating from FactoryLink to WinCC 8.0
• Systematic transfer of functions from the old network to a consistent, maintenance-friendly structure

The project was characterized by special challenges:

• Complex system analysis: The heterogeneous old system required in-depth reverse engineering of the control logic and interfaces
• High integration requirements: The large number of different systems had to be transferred error-free into a standardized Siemens architecture
• Very short project planning phase: the entire technical planning was completed in just three months

Despite the tight time frame, the project was successfully implemented. A careful and precise preliminary analysis, continuous communication with the customer, smooth installation and commissioning as well as a cooperative partnership between all parties involved were decisive for this.

The modernized automation technology increases system availability, simplifies service and maintenance and creates a sustainable basis for future expansions.