Problem:
A major pool manufacturer operated a 12-stage production line that transformed flat sheet steel into frames for above and below ground pools. Each stage including stacking, bending, notching, drilling, and assembly, ran independently with separate controls for the hydraulic pump and machinery. This required technicians to manually operate each station, slowing production and creating safety concerns.
Solution:
The production line’s programmable logic controllers (PLCs) and human machine interfaces (HMIs) were upgraded to Rockwell Automation ControlLogix and FactoryTalk ME technologies. This modernization allowed all 12 stages to be monitored and controlled from a single interface, streamlining workflow and enhancing safety.
Outcome:
Centralized control eliminated the need for technicians to walk between stations, saving time and improving efficiency. Operators can now view real-time production data, track panel counts, reset equipment, and shut down individual stages as needed—all from one location. The upgrade increased productivity, reduced manual intervention, and improved workplace safety.
