Azdel, Inc. manufactures composite sheets for headliners in the automotive industry using a process similar to that of a paper mill. Due to expanding markets, the company needed additional capacity to meet its growing demand. Azdel, Inc. added manufacturing space and purchased a new process line. Synchrony Industrial Controls was selected to provide control panel design and manufacture; integrate the process control system and the HMI operator interface into the new production line; and implement a new SPC system. Synchrony provided the following services:

• Designed and manufactured the automation system electrical control panels
• System integration of the various vendor supplied components of Line 3
• Modeled the new operator HMI interface to an existing Azdel line to ensure timely operator acceptance and efficiency
• Supplied Ethernet system from PLC to HMI to Supervisory connectivity
• Integrated additional Azdel process lines including hardware and software for SPC and analysis
• Provided installation and start-up services for supplied software
• Trained Azdel personnel in system operation

Line 3 is now in production, generating high quality product with minimal scrap. Synchrony worked closely with the plant’s maintenance personnel to insure they were intimately familiar with the automation system. The addition of SPC monitoring allows Azdel to quickly identify process variables. Azdel is so pleased with the new line and its process control and operator interface that they plan to add a sister line in the near future.