GLASS BOTTLE PLANT (HOUSTON, TX)
ACC’S main task was MES software engineering. ACC performed vendor hardware and software evaluation, German Software Development Team management, onsite cluster and network administration, data design and management, database development, and PLC controls and communication design. System used Allen-Bradley SLC 5 PLCs, Wonderware HMI, In SQL data historian and .NET web-based reporting.

PET FOOD PLANT (MECHANICSBURG, PA)
ACC managed and completed programming for the MES SUITE controls effort. The MES SUITE integrated the plant DB2 relational database, over 20 FIX32 HMIs, and over 15 Modicon Quantum PLCs. This effort provided information required to download recipes and track product usage through all plant processes.

NUCLEAR MEDICINE (ST. LOUIS, MO)
ACC played a leading role in the HMI development of an Automatic Sorting System for the St. Louis facility. One Allen Bradley PLC 5/20 processor was used, with one Intouch Wonderware HMI/SCADA networked via Data Highway Plus. ACC performed development, simulation, commissioning, and start-up.

PET FOOD PLANT (MONFORT, FRANCE)
ACC provided engineering guidance and recommendations for the selection of local system integrators to complete this effort. ACC also provided preliminary network architecture and requirements definition.

PET FOOD PLANT (DUBBO, AUSTRALIA)
ACC provided programming, commissioning, start-up, and training for a new Pet Food Extrusion Production Line. Allen-Bradley SLC 5/05 was used with RSView SCADA software. ACC consulted on many process improvement issues during this start-up process. ACC provided extensive operator and maintenance training as part of this effort.

CEREAL PLANT (BATTLE Creek, MI)
ACC played a leading role inthe HMI development and I/O layout, and a minor role in the PLC development of the Packaging Consolidation for the Battle Creek plant. One Allen-Bradley PLC 5/60, one Allen-Bradley PLC 5/40, six Allen-Bradley T60 Operator Interfaces (Allen-Bradley Control View) and two Allen-Bradley PanelViews were used. PLCs were networked via Data Highway Plus, while PanelViews were connected as Remote I/O. ACC performed development, simulation, commissioning, and start-up.

PET FOOD PLANT (ST. LOUIS, MO)
ACC developed an estimating tool for converting large-scale plants from Intellution FIX32 to iFIX. Current state of iFIX translation tools was explored to develop a base procedure for translating these programs. Based on this procedure, the Excel-based estimating tool would calculate man-hours per SCADA system.

PET FOOD PLANT (PORTOGRUARO, ITALY)
ACC provided consultation, startup support, and training for a new Pet Food Extrusion Production Line.

PET FOOD PLANT (CARACUS, VENEZUELA)
ACC provided programming and training for a Pet Food Extrusion System in Caracus. Allen-Bradley SLC 5/05, RSView, and Ethernet were all utilized.

PET FOOD PLANT (ATLANTA,GA)
ACC played the lead role in the PLC programming, HMI development, and start-up for the Atlanta Dry Byproduct Project. Specifically, ACC provided all Modicon Quantum PLC programming and iFIX HMI development. ACC completed the development, simulation, commissioning, start-up, and training for this system.

PET FOOD PLANT (FLAGSTAFF, AZ)
ACC assisted in the PLC programming, HMI development, and start-up of Flagstaff’s fourth Further Processing System. Specifically, ACC provided Modicon Quantum PLC programming and Intellution Fix32 development. ACC completed the development, simulation, commissioning, and start-up for this system.

PET FOOD PLANTS (All eighteen Nestlé-Plants)
STRATEGIC PLANNING FOR CONTROLS DEVELOPMENT
ACC authored a controls engineering survey methodology. This report will provide management insight into the level of standardization of the control systems as they exist in the plants today. Worksheets displaying evaluation criteria and plant scores are reported by process area. Results will indicate degree of compliance to standards, as well as identify areas in critical need of improvement. Risks will be quantified, prioritized, and reported. Age of control systems will be indicated and associated with a score to track effective control system life cycle. Plant controls personnel will be interviewed and allowed to report their concerns and priorities. A three year automation strategic plan for each plant will be provided, outlining the changes and additions in a prioritized order. The order will be based on risk and technological feasibility, and will leverage synergies between projects. The net goal here is to prepare a three-year roadmap to improve overall plant automation effectiveness. Worksheets can be updated periodically to provide a tool to report plant standardization progress.

METAL CONTAINER PLANT (MIRA LOMA, CA)
ACC played a leading role for the commissioning and start-up of two Spin Flangers and One Light Tester for the Mira Loma plant. Each machine consisted of an Allen-Bradley 5/30 processor and one Allen-Bradley PanelView. PLCs were networked via Data Highway Plus, while HMIs were connected using Remote I/O.

PET FOOD PLANT (DAVENPORT, IA)
ACC played the leading role in the PLC programming, HMI development, and start-up for the Davenport Plant Slurry Batching Project. Specifically, ACC provided all Modicon Quantum PLC programming and worked in coordination with another ACC engineer to complete the Intellution Fix32 development. ACC completed the development, simulation, commissioning, and start-up for this system.

PET FOOD PLANT (MECHANICSBURG, PA)
ACC managed the PLC and HMI development effort for the process areas for the Mechanicsburg pet-food re-opening effort. ACC provided seven full-time engineers dedicated to this project. The System included over 40 PLCs, 27 Intellution Fix nodes, and 30 TCP quick-panels. ACC provided standards development, programming, and start-up support for the majority of these systems. Effort included maintenanc, as well as specifying and adhering to software standard design to minimize development time and facilitate software training. ACC provided operations training and programmers/maintenance training to transition support to plant personnel.

METAL CONTAINER PLANT (ARNOLD, MO)
ACC played a role in the commissioning and start-up for a rate increase on two aluminum can manufacturing lines at the Arnold plant. Process consisted of multiple Allen-Bradley PLC 5’s interlaced with an existing Apache controller. Allen Bradley processors were networked via Data Highway Plus, while HMIs were connected using Remote I/O.

PET FOOD PLANT (OKLAHOMA CITY, OK)
ACC played a leading role in the HMI development of three Further Processing Systems for the Oklahoma City plant. Three Modicon Quantum 424 processors were used, with four Intellution FIX32 HMI/SCADA networked on Modbus Plus and IBM token ring networks. ACC performed development, simulation, commissioning, and start-up.

PET FOOD PLANT (ATLANTA, GA)
ACC played the leading role in the PLC and HMI development of the Slurry Batching System for the Atlanta plant. One Modicon 984/785 processor was used, with one Intellution DMACS HMI/SCADA networked on Modbus Plus and IBM token ring networks. ACC performed development, simulation, commissioning, and start-up.

PET FOOD PLANT (DUNKIRK, NY)
ACC played a leading role in the HMI development of four Further Processing Systems at the Dunkirk. Plant. One Allen-Bradley 5/60 processor was used, with four Intellution DMACS View Nodes and One FIX DMACS OS2 SCADA networked on Modbus Plus and IBM token ring networks. ACC performed development, simulation, and start-up.

METAL CONTAINER PLANT (ROME, GA)
ACC played a leading role in the commissioning and start-up of one Cupper and 12 Body Makers and Trimmers for the Rome plant. Each machine consisted of an Allen-Bradley 5/30 processor and one Allen-Bradley PanelView. PLCs were networked via Data Highway Plus, while HMIs were connected using Remote I/O.