Providing solutions for Yuasa

Imperium Systems provides specialist and bespoke electrical, software and industrial process control solutions to customers across the UK.

From control panel design and manufacture to working on programmable logic control (PLC) systems, human machine interface (HMI) panels and supervisionary control and data acquisition (SCADA) solutions, Imperium Systems provides a bespoke solution suited to each customer’s needs.

In the case of Yuasa, one of the world’s largest manufacturers and suppliers of lead-acid batteries with global manufacturing plants and an extensive marketing and distribution network throughout the UK and Europe, Imperium Systems was initially called in to their Ebbw Vale plant to work on two projects.

PLC Modifications

With the overall aim of improving efficiency, Imperium Systems were tasked with looking at the company’s PLC systems in order to find ways of meeting better production targets.

An advanced fault finding exercise formed the first part of the company’s approach where two main errors were discovered. Using Imperium System software, the team was able to look at the systems and analyse their performance. As a result, an acid filler tool was found to be not working properly and the scales used to calculate the fill were also not weighing correctly.

Once the problems had been fixed, Imperium Systems was able to then create new software which allowed it to perform a PLC upgrade. This offered the on site engineers the functionality of being able to work on more than one battery type, thus saving costs whilst increasing production capability.

HMI

With the PLC issues resolved, Imperium was then asked to look at the current HMI panels which were outdated and lacking in the functionality required by the production team.

Working alongside the team in order to ascertain their exact needs and requirements, Imperium Systems created new software to upgrade one panel. It then replaced three panels with new ones, and decommissioned another which was found to be redundant.

Improving Efficiency

As a result of the changes to the PLC and HMI systems, improved efficiency in terms of energy usage was also noted by Yuasa.

Documentation

With Yuasa also completing ISO 9001/2, Imperium Systems was able to assist the company by re-writing programmes for all machinery, providing manuals and service histories to ensure that all documentation required is available and up to date.

Training

Full training to on-site engineers and electricians at Yuasa is also provided on an on-going basis.

“As a result of the work Imperium Systems undertook on site, which included modifying and altering programmes to make the machine sequences more  effective, we have not only seen an improvement in production, but also a reduction in terms of energy usage. We have found the whole working relationship with Imperium Systems an  extremely positive experience and would recommend their services to anyone needing skilled expertise in this area.”

ROB WEST
Utility Engineer at Yuasa, Ebbw Vale