Brillux

Paint and coatings specialist Brillux is one the most successful manufacturers of painting products in central Europe.  The company’s warehouse and distribution operations include a fully automated conveyor system controlled by Siemens SIMATIC automated process controllers and a traditional MLOG SCADA system. 

Brillux has worked with SCHAD since 2010, implementing EXTEND7000 as a mobile SCADA system to give engineers ‘anywhere-anytime’ alerts. This means they receive real time notifications of system performance issues if a problem occurs within the company’s primary distribution centre in Munster. In addition, they have the ability to gain remote access to automated control systems to investigate system performance issues, using a standard BlackBerry smartphone. Alerts are sent immediately, directly to the appropriate member of the technical team in real-time, according to a pre-defined escalation scheme. 

Secure mobile SCADA means ‘anywhere-anytime’ control
The system uses existing Wi-Fi or GPRS infrastructure thereby providing a low cost, functionally rich mobile control and monitoring solution. Before integrating EXTEND7000 with existing Siemens process controllers, Brillux undertook an extensive analysis of the software’s functionality and efficiency.

“We precisely collect and analyse data on our downtimes,” says Uwe Lemmer, head of product distribution at Brillux. “During the EXTEND7000 test phase we were watching particularly closely to see what the new software could bring us. The results however were convincing.” 

EXTEND7000 works by granting secure remote access to Brillux’s complex conveyor systems and stacker cranes at its distribution centre for engineers. With the software, authorised employees can control and monitor materials handling control systems directly using mobile devices connected to Siemens SIMATIC controller handling technology.

Better productivity, faster issue response times
Prior to adopting EXTEND7000 from SCHAD, information relating to the continuous smooth running of automated systems in the warehouse would be displayed visually, in a dedicated control room staffed by warehouse engineers.  Employees who were previously restricted to the control room to monitor signal levels and delegate tasks by phone, can now actively take control of all core troubleshooting tasks, without having to interpret details by phone or text message.  Routinely engineers are free to undertake additional assignments because all notifications and alerts are continuously remotely monitored and, with installed storage and retrieval camera systems, EXTEND7000 enables retrievable checks.  Any failure can also be linked to the relevant camera image allowing a single failure to be visually checked and evaluated.

28% reduction in downtime
EXTEND7000 has helped Brillux shorten reaction times and to reduce unscheduled downtime of conveyor systems by 28%.  Faults are now detected quickly, analysed and corrected.

“With the data received from EXTEND7000 it is possible for engineers to go directly to the point of any fault without having to first visit the control room and collect the necessary details. The SCHAD software thus enables us to dramatically reduce response times after failure,” says Uwe Lemmer.

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