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Federal Mogul

Valve Guide Rotary Machines (Mitsubishi PLC Upgrade)

Project Description:  Federal Mogul, a leading manufacturer of engine components selected MCS Control Systems to replace 13 obsolete Mitsubishi PLC’s in their precision valve guide facility with minimum downtime and disruption.

Approach:  It was assumed many of the machines had the same program. Software for all machines was examined and verified. Due to the configuration and available stoppage times, a phased approach was not possible, i.e. CPU transplant followed by an I/O transplant. For this project the “big bang” approach was adopted where the entire PLC complete with I/O and wiring was replaced in a single shutdown.

Following the successful transplant of the first PLC, the second, third, and so on were done by adopting the same strategy. At all stages the customer was kept informed to ease his concerns. MCS always had a back up plan in case any thing went wrong and to minimize risk. MCS provided standby cover in the event of any issues but this was not required as the system ran sweetly as before the transplant. In some cases the change over was so quick and smooth the operators did not realize that the machines had been up graded.

Results:  All 13 PLC’s were successfully transplanted over a period of 6 months with minimum down time and loss of production.