Motherson Paint Shop:
A Journey from Vision to Reality
A remarkable transformation has been unfolding inside the massive Motherson factory in the middle of Germany. Samvardhana Motherson Peguform is a leading expert in high-quality interior and exterior modules for the automotive industry. It’s a story of perseverance, adaptability, and a small but mighty company’s ability to tackle the most significant challenges.
Welcome to the Motherson project, a new painting line for plastic car parts that has not only tested the limits of technology but also showcased the expertise of a company determined to make it all work.
ASIS partnership
The Motherson project began as a typical ventilation project but quickly morphed into something more ambitious. ASIS GmbH, our sister company, embarked on a mission to construct a state-of-the-art painting line.
Drawing from Boreto’s prior experience with ventilation (HVAC) systems, the decision to entrust us with the entire ventilation system and an additional machine known as the Regenerative Thermal Oxidizer (RTO) was a natural one.
Our role in the project
Boreto’s role in the Motherson project was multifaceted. We undertook the responsibility of electrical planning, software development, and visualization preparation. However, our most critical role was ultimately commissioning the ventilation system (VT) and the RTO. This was a task that demanded precision and dedication.
Challenges
Every project, regardless of its scope, has its share of challenges. For the Motherson project, the challenges were substantial. Firstly, the global delivery problem that has plagued industries worldwide also made its presence felt here. This meant constant engineering and reengineering to align with ever-shifting delivery schedules.
Drawing from experience
One of the key strengths of Boreto is its ability to learn from past projects. The experience gained from Project V-Zug served as a valuable foundation for the SMP Line project. However, this endeavor came with its unique demands, necessitating flexibility and adaptability in our approach to project planning and customer requirements.
The technologies used
The Motherson project converged various technologies, such as Eplan, the TIA Portal, Data analytics, and Regenerative Thermal Oxidizer. Eplan and TIA Portal were instrumental in our electrical planning and software development efforts. Data analytics plays a crucial role in optimizing system performance. The Regenerative Thermal Oxidizer (RTO) was the cornerstone of the project, ensuring environmental compliance in the painting process.
What we did: The result
After countless hours of hard work, dedication, and overcoming obstacles, the Motherson project achieved its primary goal: a fully operational painting line. It’s a testament to our technical prowess and a realization of the trust that ASIS GmbH had in our capabilities.
A company’s success
For Boreto, the Motherson project was a defining moment. It demonstrated that the company’s size doesn’t limit its ability to handle significant projects. It’s a testament to our knowledge of ventilation and HVAC systems and our unwavering commitment to success.
The Motherson project is not just a story of machines and technology; it’s a tale of determination, resilience, and the triumph of expertise over adversity. It’s a reminder that, in the face of challenges, small companies can achieve remarkable feats when armed with the proper knowledge and a dedication to excellence.
The Motherson Paint Shop now stands as a testament to this truth, painting a brighter future for the automotive industry and those who dare to dream big.
Join our dynamic team and become a key player in our journey towards achieving even greater milestones. Explore career opportunities and become a part of our commitment to excellence in engineering and innovation.
Streamlining Production: AD Plastik's Success Story with CO2 Cleaning Robots
In today’s fast-paced manufacturing world, efficiency is the key to success. AD Plastik, a leading player in the industry, recently undertook a remarkable project that showcased their commitment to innovation and efficiency.
In just three weekends, or six days in total, we successfully integrated two CO2 cleaning robots into their existing production line, all while ensuring minimal disruption to their operations.
The challenge: Commissioning in record time
AD Plastik faced a daunting challenge – integrating two CO2-cleaning robots into their production line within a remarkably short timeframe.
What made this endeavor even more challenging was keeping the production line running seamlessly throughout the process. Any delays or disruptions could lead to significant losses in time and resources, which you always want to avoid.
The problem
A tight timeline was the main problem, and to achieve the goal, Boreto had to collaborate with an additional company. This meant coordinating with external partners while minimizing plant downtime. The pressure was on to ensure everything ran like clockwork.
The first weekend, two PLC programmers and two ASIS robotic programmers already did the automatic test with line tracking parts on the conveyor.
For the second weekend, setting up the CO2 application took almost two full days of work in the cleaning booth. A well-known problem with commissioning is when more people need the time to install and/or test different equipment in the working area. Fortunately, we had an additional two days due to the holiday time.
Technologies used: Precision and innovation
To tackle this ambitious project, we relied on technologies, such as Eplan, Simatic Step7, TIA Portal, and the cutting-edge Robot CO2 cleaning system. These technologies enabled precise control and monitoring throughout the integration process.
Integrating these advanced technologies underscores our commitment to staying at the forefront of automation and manufacturing innovation.
Investing in these tools and expertise helped us achieve their immediate goal of integrating CO2-cleaning robots and future-proofing our operations. This enables us to adapt swiftly to evolving industry demands and maintain a competitive edge in the market.
The results: Efficiency and cost savings
The successful integration of the CO2 cleaning robots was a game-changer for AD Plastik. It streamlined the production process and led to significant cost savings.
The goal: A glimpse into the future
Our achievement serves as an inspiring example for other production plants.
Our ability to complete a complex integration in such a short time demonstrates the potential for fast and flexible commissioning, even when dealing with new and advanced technologies.
This success story highlights the importance of innovation and efficiency in modern manufacturing.
AD Plastik’s integration of CO2 cleaning robots in only 6 days is a testament to our dedication to pushing the boundaries of what’s possible in manufacturing.
It underscores the immense potential for rapid and efficient commissioning, offering a glimpse into the industry’s future.
As the demand for automation and efficiency continues to grow, AD Plastik’s success story is a shining example of what we can achieve with the right mindset, technology, and teamwork.