Case Study

AB SLC 500 PLC: Rapid Response and Expertise Save Production Line for Out-of-State Stainless Sheets Manufacturer

Problem faced:

Allen Bradley SLC500 PLC Fault

A prominent out-of-state manufacturer of stainless sheets and bar stock faced a critical production halt when one of their production lines unexpectedly went down. The issue was traced back to a PLC (Programmable Logic Controller) fault, which refused to reset, threatening significant financial loss and potential downstream impacts on their customers and the ultimate end users. The urgency of the situation was compounded by the immediate financial implications of production downtime. The complexity of the problem required not only the right equipment to diagnose and fix the PLC but also specialized knowledge to troubleshoot the sophisticated software and hardware involved.

AFI Systems solution:

1746-Ni8 Programming Service Call

Upon receiving the service request, AFI's engineer was quick to mobilize, emphasizing the critical nature of response time in such scenarios. Equipped with a laptop, necessary connection cables, and software to communicate with the PLC, the engineer embarked on a road trip to the customer's site, ready to tackle the challenge head-on. The technician’s expertise in reading and troubleshooting PLC programs, along with his ability to trace wires and understand schematic diagrams, proved invaluable. The root of the problem was identified as a malfunction in a secondary PLC, which caused the primary PLC to fault due to faulty inputs to an Allen Bradley 1746 NI8 module. Fortunately, AFI’s foresight in saving customer programs meant the engineer could quickly download the necessary program to the malfunctioning PLC, effectively resolving the issue and restoring the production line to full operation.

Result:

Professional Allen Bradley PLC Repair

The rapid response and technical acumen of AFI's engineer not only saved the customer from extended downtime and financial loss but also underscored the importance of having a reliable service partner capable of dealing with legacy systems like the AB SLC 500 PLC. This incident highlights AFI’s commitment to customer service and its ability to provide swift, expert solutions to complex problems. The successful resolution of this case not only ensured the manufacturer could resume production without significant delay but also reinforced the value of AFI’s services in maintaining the reliability and efficiency of aging industrial systems. For potential customers facing similar challenges with their production lines, AFI stands out as a partner equipped with the expertise, responsiveness, and resources to keep operations running smoothly, regardless of the complexity or urgency of the issue.

Field service - standard AFI practices

Whether you call or send an email to us, you will get through to someone who can help schedule one of our technicians to come to your facility quickly. Most industrial or manufacturers have tight operating or production schedules where there is never a good time for a machine or critical piece of equipment to break down. Get back to operating quickly again with AFI Systems. Consider these advantages:

• We come to you to ensure the fastest field service possible - usually within a day or two.
• Our technicians can inspect your entire machine/equipment for potential issues - both electronic and mechanical problems are common, and the real problem is not always obvious!
• Any issues that cannot be resolved on-site will travel back to our factory with the technician.

We believe in being accessible. Our account managers / customer service team promptly answers incoming calls, and provides quick responses to incoming emails. Many of our customers have 24/7 schedules and we always try to service their needs accordingly.

Contact us today to see how AFI Systems can service your food or beverage manufacturing equipment!