Transcript Document

An Introduction To
The KEY Group Organisation
Corporate Mission Statement
“KEY Group Solutions Limited is a privately owned UK Company, offering full
Turnkey Project Solutions within the Automotive, Aerospace and leading
Manufacturing and Process Industries.”
“Working Closely with the customer to maximise their requirement, the latest
‘State of the Art’ Technology, enables KEY Group to develop the most
appropriate and cost effective solutions for our international clients.”
“Offering the ‘Best Available Technology’ and developing with the customer the
smooth transition of Technology Transfer emphasises our commitment to
Continued customer support.”
Kevin Dodson – Managing Director
Our Background
Privately Owned Group Of Companies
Established In 1999
Turnkey Supplier To Automotive & Process Finishing Industry
Central UK Location With Midlands Based Offices
Efficient Seamless Infrastructure
Suppliers Of ‘Cutting Edge Technology’
KEY Supports A Fully Integrated Documented Quality System
Corporate Structure
KEY Technical Solutions
KEY Property & Developments
KEY International Projects
UK Turnkey Projects
Residential & Commercial
Property Portfolio
Overseas Projects
Control System Solutions
Property Asset Management
25,000 UPA Paint Shop
Successfully Completed
102 Projects
Building / Property Development
10,000 UPA Engine Facility
KEY Head Office
Ideal ‘Back Bone’ Of The KEY Organisation
10,000 sq. ft of Prestigious Offices In Central UK
Management and Engineering Personnel
Fully Integrated IT Networked Systems
Customer Training Facilities
Management Team
Name: Kevin Dodson
Managing Director
Experience: 27 Years
- Corporate Management Skills
- Global Automotive Business
Development
- Team Leader
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Name: Ron Carter
Contract Manager
Experience: 30 Years
- Hardware System Design
- PLC & SCADA System
Design
- Electrical Project Management
Name: Gordon Wilkie
Finance Manager
Experience: 12 Years
- Accountants Administration
- Procurement Processes
- Team Leader
Name: Ian Lavender
Technical Manager
Experience: 19 Years
- APT Commissioning Specialist
- Resistance Welding Engineering
- Technical & Service Support
- Maintenance Management
1st Tier Supplier Status
Airbus
Jaguar - Halewood
- Paint Shop Control Room
- Upgrade of Machine
Tools Inc. Safety
Upgrades
BMW - Plant Oxford
- Paint Shop Control Room
- Building Management
System
- Trim & Final Control
Room and Networks
Land Rover
- High Velocity Blowers
- Booth & Tunnel Mods
- Diesel Engine Line
Relocation
- V8 Engine Line
Relocation
MG Rover Cars
- Paint Shop Networks
- Paint Mix Control Room
and SCADA graphics
GM Fiat - IBC Luton
- Upgrade Of Paint
Application Equipment
- Installed Paint Machine
Control Systems
Peugeot
- Upgrade Of Primer
Painting Facility
- New Operator PC
Graphics
Vauxhall
- Paint Shop Control Room
- Paint Application Upgrade
- Paint Application Systems
Primer and Colour Lines
- Paint Mix Upgrade
- 'K' Series Engine
Assembly Upgrade
- ARP & Exhaust Fan
System Upgrade
Core Products
SprayStation©
‘A graphical user workstation designed
for the complete control of an Automated
Paint Application process’
- Unlimited Style & Colour
Quantities
- Open Architecture
Database
- Extensive Production &
Management Reporting
- Comprehensive Alarm
Management
Core Products (Cont.)
‘Retractable Booth Flooring’
Minimum Impact On Air Flow – Reduced Cleaning Costs
Proven Experience You Can Trust
“KEY possess a wealth of project management experience
and as a result are positioned to undertake contracts of
any scale or duration.”
“KEY are able to provide the role of ‘Principal
Contractor’ as defined within the CDM regulations.”
“KEY offer Process Engineering support and design
services that ensure our customer utilise ‘Best In
Class’ processes at every stage.”
“From process optimisation to complete facility layout
and design our engineers can help your business.”
KEY Core Capabilities
Project Management and Principal Contractor
Industrial Process Plant Supplier
Mechanical and Electrical Design
Computer Aided Design (CAD)
PLC Control Software Design
Management & Supervisory Computer Systems
Complete Plant Wide Integrated Solutions
Services & Facilities Management
Feasibility Studies
Business Requirement Documents
Functional Design Specifications (FDS)
Procurement
International Freight Forwarding
Mechanical & Electrical Installation
Commissioning & Robot Programming
Engineer & Operator Training
Site Support Services
KEY Fields Of Expertise
Total Factory Integrated Solutions for:
Press Shop
Body-In-White
Paint Shop
Trim & Final
Power Train
KEY Fields Of Expertise (Cont.)
Body-In-White Processes:
Adhesive / Sealant Booths, Robotic Welding Cells,
Highlighting Booths, Panel & Body Wash Systems,
Forming Machines, Assembly & Finishing Solutions
Paint Shop Processes:
Pre-Treatment, Electro-Coat Painting, Spray Booths
& Enclosures, Infra Red & Conventional Ovens, Air
Replacement Units, Paint Mix Systems, Paint
Application Equipment, Water Treatment Plants,
Thermal Oxidisation
KEY Fields Of Expertise (Cont.)
Trim & Final Assembly Processes:
Robotic Glazing Cells, DC Tooling, Fluid Farms &
Dispensing Systems, Water / Strom Test, Line
Side Logistic Systems
Power Train Processes:
CNC Machining Centres, Automated Assembly
Machines, Leak Test, Final / Sub Assembly Lines,
Hot & Cold Test, Robotic Component Handling
An Overview Of
KEY Expertise & Project Experience
“Control System Solutions”
Control System Solutions & Electrical Installation
A corner stone of the KEY organisation is the design, manufacture
and installation of ‘Turnkey’ Control System Solutions.
Whether it’s a large ‘Turnkey’ Control System project with a complex
suite of panels, or modifications to an existing system our experienced
team are able to provide a solution.
KEY has a dedicated ‘In-House’ design team working with
the latest software packages to deliver Innovative ‘State of
the Art’ System Solutions.
All site installations are managed and undertaken by our
specialist team in full accordance with our own quality
procedures and CDM regulations.
KEY are also able to offer a range of bench test and modular
build services as well as final commissioning, PLC Software
Design and Robot Programming.
Control System Solutions & Electrical Installation (Cont.)
Full ‘Turnkey’ Control System Project & Contract Management
Innovative ‘State of the Art’ System Solutions
Complete System Design and Electrical Drawings
Comprehensive Range of Standard Drawing Packages
All Systems Fully Compliant to Latest International Standards
Extensive Experience In Working Within ‘EX’ Rated Environments
No Commercial Ties To Any Equipment or PLC Suppliers
Electrical Equipment Procurement and Delivery
Dedicated In-House Site Management & Installation Team
In Excess Of 30 Years Experience In Large Installations
Established Safe Working Practices In Line With CDM
Low Voltage (LV) and High Voltage (HV) Systems
Modular Build and Bench Testing Of Systems
System and Software Commissioning Services
Durr (APT) – Robotic Paint Application Equipment
Durr (APT) selected KEY to work as their partner in the first UK
installations of their highly successful 7 axis Paint Application Robots.
Resulting in a number of complete ‘Turnkey’ electrical Control System
Projects.
The role of KEY was the ‘Turnkey’ supply of the electrical Control System
and associated panel suite for the individual robots. The scope of supply
Included; design, manufacture and site installation.
The systems were each modular built prior to final
installation, with KEY providing a full team of both electrical
and commissioning engineers during this critical project phase.
The final systems when installed at the customers sites were
fully integrated into existing Plant Wide PLC, Network and
SCADA systems to provide the ultimate solution.
Durr (APT) – Robotic Paint Application Equipment (Cont.)
Full ‘Turnkey’ Robotic Electrical Control System Projects
Electrical and Software Contract Management
Complete Control System Design and E-Plan Drawings
Electrical Component and Equipment Procurement
Manufacture of Control Panel Suites & Bench Test
Modular Build of System at Durr Factory In Germany
Electrical and Software Support of Modular Build Phase
Electrical Field Installation at Clients Facility Utilising In-House Team
Site Management In Accordance With Safe Working Practices & CDM
Equipment Installed Within an ‘EX’ Rated Environment
Final Systems Fully Commissioned and Documented
All Projects Completed On Time and Within Budget
Jaguar – Castle Bromwich – SVO Control System
The Special Vehicle Order (SVO) Control System installed within the
Paint Shop at Jaguar Cars Castle Bromwich caters for the painting of
‘one’ off vehicles to satisfy specific colour requests of the customer.
The paint application equipment was based on the latest ‘Push-Out’
colour change technology in order to keep paint usage to an absolute
minimum. Implementation of this required KEY to redesign the electrical
Control System to cater for additional Air, Paint and Solvent Valves.
The existing Modicon 984 PLC equipment was replaced with a new
Quantum Series solution fitted with a Co-Processor to mange the
expanded Paint Application and Colour Change data.
The existing remote Input/Output (I/O) racks were added to
encompassing the control of the additional valves. The I/O racks
were accessed by the main PLC Processor via new Remote I/O
Scanner cards.
Jaguar – Castle Bromwich – SVO Control System (Cont.)
Complete ‘Turnkey’ SVO Paint Application Control System
Conversion of 9 Bell Basecoat ESTA and 6 Gun Reciprocator Zones
Modicon 984 PLC’s Replaced With New Quantum Series Equipment
Expanded Paint Data Managed Via Introduction of Co-Processors
Additional Remote I/O Racks Handling New Paint, Air and Solvent Valves
Replacement Electrical Drawings In E-Plan CAD Format
PLC Software Expanded and Converted From 984 to Quantum Logic
New Interface to Communicate With Durr ECO Paint SCADA System
Design of Software Interface Between PLC and BOSCH Motion Controller
Full Electrical Installation and Modification of Existing Panel Suites
Final System Commissioning, Operator Training and Production Support
“SCADA & Network Systems”
Factory Integrated SCADA and Network Systems
KEY has developed a reputation for the design and implementation
of ‘Bespoke’ Graphical Operator Interfaces and System Controls.
What ever your business demands whether a Plant Wide Integrated
SCADA system or a local Human Machine Interface (HMI) our team
of software designers will deliver a user friendly solution built to suit
your needs.
Comprehensive Management and Production reporting
systems can be realised with the use of standard software
packages such as Microsoft SQL or Access.
KEY are also pleased to offer our clients an extensive range
of network solutions designed to collate the data required to
generate meaningful operator screens.
Factory Integrated SCADA and Network Systems (Cont.)
Designed to Suit Customers Specific Needs
Monitor and Control Plant Wide Machines & Facilities
Production and Management Reporting Systems
Standard Software Applications and Tools, Including
GE Cimplicity
Wonderware
RS View / Panel Builder
Factory Integrated Network Solutions
Ethernet
RS 485 / 232
Dedicated PLC I/O Networks
Wi Fi Communication Systems
All Systems Fully Developed & Commissioned In-House
Comprehensive Documentation & Customer Training
Microsoft – SQL & Access Databases
BMW – Vehicle Management System (VMS)
The Vehicle Management System (VMS) is utilised within the Paint
Shop at BMW Plant Oxford to both graphically ‘Map’ the location
of all bodies currently travelling through the facility, and also manage
Colour, Style, Storage Locations and Production Flow.
VMS interfaces directly with existing BMW logistic systems in Germany
to determine customer order derivatives. The collated data is tracked
with the body as it travels through the facility which is automatically
transferred to the Paint Application and Process equipment as required.
The VMS system provides a vast range of both automatic and
manual routing controls, which include full control of Conveyor
Strip Out and Storage areas to cater for optimised production
flow.
The final solution was based on Allen Bradley Control Logix
PLC systems and GE Cimplicity SCADA Graphic packages.
BMW – Vehicle Management System (VMS) (Cont.)
Special Purpose SCADA & PLC Based Vehicle Management System
Fully Designed and Implemented In Partnership With The Customer
Comprehensive Range of ‘User Friendly’ Graphics and Features
Interfaces Directly With BMW Systems To Manage Vehicle Derivatives
Logistic and Production Management Tools To Control Production Flow
‘State of the Art’ Allen Bradley Control Logix PLC Solution
‘Hot Standby’ PLC Eliminates Downtime In This Mission Critical Systems
Communicates With Paint Application Equipment To Manage Body Colour
Networked Baumer Bar Code Readers Utilising The RS485 Protocol
Microsoft SQL Production and Management Report System
Configurable Microsoft Access Based Production Reporting System
Dynamic Production Statistic Summary – Real Time Vs Target
Vauxhall Motors – SCADA and PLC Upgrade
Vauxhall Motors awarded KEY the prestigious contract to upgrade the
existing SCADA and PLC systems utilised within the Paint Shop facility
at their Ellesmere Port Plant.
The basis of the project was to upgrade the existing GE Fanuc Cimplicity
SCADA package to the latest revision. Whilst performing the upgrade all
existing screens were reviewed to improve graphical representation and
functionality.
In addition the existing Series 6 PLC equipment was upgraded and
replaced with new Processors, Main Racks and Ethernet Modules
from the GE 90/70 Range.
The Genius I/O networks were reconfigured to connect to the new
Processors and the whole solution was integrated into the Plant Wide
Ethernet network.
Vauxhall Motors – SCADA and PLC Upgrade (Cont.)
Upgrade of GE Cimplicity SCADA Package To Latest Revision
All New Screens To Provide Improved Appearance & Functionality
Integration of Final SCADA Solution Into Plant Wide Graphics System
Automated Plant Start & Stop Sequences From Within SCADA
Installed Xycom Flat Panel Operator Touch Screen Terminals
Replace Existing PLC’s With Equipment From GE Fanuc 90/70 Series
Expanded Plant Ethernet To Accommodate New PLC Systems
System Modifications Undertaken In Non Productive Weekend Periods
The Process Equipment Upgraded Included :Paint Mix
Air Replacement Plants
Paint Application Booths
Primer and Colour Ovens
“Turnkey Projects”
Electro Mechanical Turnkey Projects
KEY Group offer full Electro Mechanical ‘Turnkey’ Solutions to
The Automotive, Aerospace and leading Manufacturing and Process
Industries.
The KEY Group are renown for solutions that provide ‘Cutting
Edge’ and Best Available Technologies. Fully supporting the
principle of complete Technology Transfer.
KEY Group have a reputation for completing full ‘Turnkey’
Projects, within budget and on time.
It is this level of experience in design, installation and
contract management that provides the confidence to
undertake projects of any scale.
Our customers can rest assured that any project managed
by KEY will be completed without risk.
Electro Mechanical Turnkey Projects (Cont.)
Full ‘Turnkey’ Industrial Process Plant Supplier
Principal Contractor & Planning Supervisor as Defined In CDM
Complete Electrical and Mechanical Facility Design
Civil Engineering and Design Capabilities
Computer Aided Design (CAD) and E-Plan Services
Programmable Logic Controllers (PLC) Software Design
Plant Wide Integrated Network Solutions
Functional Design Specifications (FDS)
Feasibility Studies and Proposals
Business Requirement Documents
Global Procurement Processes
Electrical and Mechanical Installation Teams
Commissioning and Robot Programming
Engineer and Operator Training
Land Rover – High Velocity Blowers
Land Rover – Solihull needed to increase their already high quality
Standards with the introduction of ‘High Velocity Blowers’ into each
of their five existing Paint Application Booths.
The Blowers and associated tunnels were designed to be directly
integrated into existing Paint Booths, with conveyors systems being
modified to direct the bodies through the Blower enclosures.
When completed Blowers remove all loose ‘debris’ from
the bodies prior to final Paint Application achieving the
required increase in quality standards.
KEY Group undertook the roles of both ‘Principal Contractor’
and ‘Planning Supervisor’ in accordance with current CDM
Regulations.
Land Rover – High Velocity Blowers (Cont.)
Principal Contractor and Planning Supervisor Roles
Complete ‘Turnkey’ Project Solution
Five Complete ‘High Velocity Blower’ Systems
Seamless Integration Into Existing Paint Application Booths
Automatic Body Recognition System For Contour Profiling
Complete Electrical and PLC Control System
‘Bespoke’ SCADA Package For Input of Parameters & Contour
Mechanical and Electrical Installation Utilising In-House Team
Complete Mechanical and Electrical Conveyor Modifications
System Commissioning and Contour Programming
Works Undertaken and Completed Within Shutdown Periods
Production Launch Support and Operator Training
MG Rover Powertrain – ‘L’ Series Diesel Line
MG Rover – Powertrain contracted KEY Group to re-locate and
re-engineer the ‘L’ Series Diesel Engine Line.
Undertaking the role of Principal Contract the existing facility was
de-commissioned, stripped out, transported from Land Rover Plant and
installed within a new two storey Powertrain facility at MG Rover
Longbridge.
KEY re-engineered the complete assembly process resulting in a
configuration from 170 metres with 60 stations to 120 metres and
45 stations and included off-line test facilities.
The complete program of works was concluded in just 9 weeks from
removal to first production units at the new location.
MG Rover Powertrain – ‘L’ Series Diesel Line (Cont.)
Full ‘Turnkey’ Project and Principal Contractor as Defined In CDM
Disassemble and Transportation From Land Rover Solihull
Original Process Length of 170 Metres / 60 Stations
Re-engineering for New Process Length of 120 Metres / 45 Stations
Complete New Electrical Field Installation
Re-Calibration of DC and Pneumatic Tooling
Commissioning, Operator and Engineer Training
9 Weeks Total Program of Works
Production Launch and Quality Support
“Facility Upgrades”
Existing Facility Up-Grades and Refurbishment
The modern day business model demands that organisations
operate with maximum productivity and efficiency, in order to be
able to compete in the Global Market.
Recognising this fact KEY are able to offer our clients a range of
services aimed at achieving these shared goals.
Frequently the business needs of our clients dictate that the
life of an existing facility or flexibility must be increased, with
this in mind KEY are pleased to offer tailored Refurbishment or
Upgrade Packages.
KEY appreciates increases in energy costs often place strains on
a clients operational budget.
KEY has developed a range of site studies and engineering
services focused on the reduction of energy usage.
Existing Facility Up-Grades and Refurbishment (Cont.)
‘Turnkey’ Facility Refurbishment and Upgrades
Refurbishment of Existing Equipment
New or Additional Equipment and Facilities
Electrical or Mechanical Projects
Maintenance Engineering and Support Services
Productivity and Flexibility Improvements
Business Requirement Documents
Facility Feasibility Studies and Reports
Energy Reduction Surveys and Proposals
Energy Efficient Motors
Inverter Motor Control
Replacement Pumps & Fans
Capacity to Manage Projects of Any Scale
Perkins Engines – Vista 3 Cylinder Head Line
Perkins Engines (Peterborough) needed to increase the production
volume of their existing Vista 3 Cylinder Head Manufacturing facility
from 14 to 16 Units Per Hour.
In order to achieve the desired increase in volume it was necessary
to introduce two new CNC Machining Centres with automated Robotic
loading. In addition the process / assembly equipment layout was
revised and new Inter Machine Component Handling System installed.
The fully automatic Inter Machine Component Handling System
was fitted with a new Telemecanique based Electrical Control
System and associated PLC software.
New Over Conveyor Coolers were installed on the exit of the
Chemical Wash machine to allow for manual handling of
the machined component through the quality inspection station.
Perkins Engines – Vista 3 Cylinder Head Line (Cont.)
Increased Production Capacity From 14 to 16 Units Per Hour
Two Additional New Agile CNC Machining Centres
Revised Layout of Process and Assembly Equipment
Fully Automated Inter Machine Component Handling System
Powered Roller Conveyors
Component Lift and Orientation Stations
New Telemecanique Based PLC Control System and Software
Replacement Electrical Field Installation and Devices
New Scissor Lift Pallet Load Into Machining Cell
Installed Manual Handling Assistors at Non Automated Stations
New Over Conveyor Component Cooling Facility
All Works Completed Within a 2-Week Shut Down Period
BMW – Inverter & Pump Upgrade
The objective of the project within the Paint Shop at BMW Plant Oxford
was to analyse the annual energy usage and investigate methods of
reducing operational costs without impact to either volume or quality.
In order to develop recommendations a detailed survey was conducted
to encompass all pumps and fans within the facility. The outcome was a
clear understanding of both existing operational conditions and equipment
efficiency.
It was identified that the most cost effective method of achieving the
required energy savings would be the installation of Inverter Motor
Controls to a number of existing Pre-Treatment Pumps and main
Spray Booth Exhaust Fans.
It was also discovered that the existing pumps within the
CO-AG Plant were both oversized and expensive to maintain,
resulting in the replacement of the entire pump units.
BMW – Inverter & Pump Upgrade (Cont.)
Specialist Project To Reduce Energy Usage With the Paint Shop Facility
Detailed Site Survey of All Equipment With High Energy Consumption
Full Written Report of Findings With Reduction Proposals
Comprehensive Study of Cost Effectiveness of Individual Proposals
Customer Agreed Strategy of Achieving Desired Reduction In Energy
Installation of Inverter Motor Control To Pumps and Fans
Modification of Control Systems To Incorporate Inverter Control
Electrical and Mechanical Installation of New CO-AG Pumps
Full Update of E-Plan Drawings and Maintenance Documentation