WEBVTT NOTE duration:"00:08:08" NOTE recognizability:0.814 NOTE language:en-us NOTE Confidence: 0.820135530666667 00:00:20.550 --> 00:00:22.040 Hi. I'm Nicole Bulanda from NOTE Confidence: 0.820135530666667 00:00:22.040 --> 00:00:23.530 Rockwell Automation and we're here NOTE Confidence: 0.820135530666667 00:00:23.579 --> 00:00:25.069 to talk about results achieved. NOTE Confidence: 0.820135530666667 00:00:25.070 --> 00:00:27.128 I'm joined by two people today by NOTE Confidence: 0.820135530666667 00:00:27.128 --> 00:00:29.013 David and Antonio to talk about NOTE Confidence: 0.820135530666667 00:00:29.013 --> 00:00:30.573 some great results that were NOTE Confidence: 0.820135530666667 00:00:30.573 --> 00:00:32.530 achieved at Chicago Heights Steel. NOTE Confidence: 0.820135530666667 00:00:32.530 --> 00:00:35.330 Hi, David. Hi, Antonio. NOTE Confidence: 0.820135530666667 00:00:35.330 --> 00:00:36.442 So let's start with you, Antonio. NOTE Confidence: 0.820135530666667 00:00:36.442 --> 00:00:39.160 Can you tell us a little bit about AIC, NOTE Confidence: 0.820135530666667 00:00:39.160 --> 00:00:41.074 your company and how you got NOTE Confidence: 0.820135530666667 00:00:41.074 --> 00:00:42.350 involved in this project? NOTE Confidence: 0.820135530666667 00:00:42.350 --> 00:00:45.738 Yeah, AIC is a system integrator with NOTE Confidence: 0.820135530666667 00:00:45.738 --> 00:00:49.170 a steel industry since it was founded. NOTE Confidence: 0.820135530666667 00:00:49.170 --> 00:00:51.865 And we met Chicago I still because NOTE Confidence: 0.820135530666667 00:00:51.865 --> 00:00:54.026 they were having some special NOTE Confidence: 0.820135530666667 00:00:54.026 --> 00:00:55.886 requests for their mill. NOTE Confidence: 0.820135530666667 00:00:55.890 --> 00:00:57.155 David, what's your role at NOTE Confidence: 0.820135530666667 00:00:57.155 --> 00:00:57.914 Chicago Heights Steel? NOTE Confidence: 0.820135530666667 00:00:57.920 --> 00:00:59.726 And tell us a little bit about NOTE Confidence: 0.820135530666667 00:00:59.726 --> 00:01:00.840 what the company does. NOTE Confidence: 0.820135530666667 00:01:00.840 --> 00:01:03.774 I'm in charge of engineering electrical NOTE Confidence: 0.820135530666667 00:01:03.774 --> 00:01:06.282 and mechanical maintenance to the NOTE Confidence: 0.820135530666667 00:01:06.282 --> 00:01:08.206 facility rerolling rail steel. NOTE Confidence: 0.820135530666667 00:01:08.210 --> 00:01:12.326 And we were facing issues with the NOTE Confidence: 0.820135530666667 00:01:12.330 --> 00:01:15.850 automation equipment that we had at the time. NOTE Confidence: 0.820135530666667 00:01:15.850 --> 00:01:16.930 We were having too many, NOTE Confidence: 0.820135530666667 00:01:16.930 --> 00:01:18.310 too many problems with it then. NOTE Confidence: 0.820135530666667 00:01:18.310 --> 00:01:21.248 That's kind of what brought us to, you know, NOTE Confidence: 0.820135530666667 00:01:21.248 --> 00:01:23.270 search for a partner that could help us with, NOTE Confidence: 0.820135530666667 00:01:23.270 --> 00:01:25.028 with, you know, finding a solution. NOTE Confidence: 0.820135530666667 00:01:25.030 --> 00:01:26.886 So tell us a little bit about this NOTE Confidence: 0.820135530666667 00:01:26.886 --> 00:01:28.289 process that we're controlling. NOTE Confidence: 0.820135530666667 00:01:28.290 --> 00:01:32.347 We get the old railroad rail, OK, NOTE Confidence: 0.820135530666667 00:01:32.347 --> 00:01:34.986 pull out of the ground after they NOTE Confidence: 0.820135530666667 00:01:34.986 --> 00:01:38.306 serve the useful life for a train tracks. NOTE Confidence: 0.820135530666667 00:01:38.310 --> 00:01:41.740 Then we get him into small sections. NOTE Confidence: 0.820135530666667 00:01:41.740 --> 00:01:43.640 And then we reheat them. NOTE Confidence: 0.820135530666667 00:01:43.640 --> 00:01:45.200 It's sliding into three pieces. NOTE Confidence: 0.820135530666667 00:01:45.200 --> 00:01:45.589 The. NOTE Confidence: 0.820135530666667 00:01:45.589 --> 00:01:49.620 The head, the web and the flange of the rail. NOTE Confidence: 0.820135530666667 00:01:49.620 --> 00:01:51.986 And then we roll a product out NOTE Confidence: 0.820135530666667 00:01:51.986 --> 00:01:54.379 of each one of those pieces. NOTE Confidence: 0.820135530666667 00:01:54.380 --> 00:01:57.999 So we are basically recycling you know, NOTE Confidence: 0.820135530666667 00:01:58.000 --> 00:02:01.440 rail steel back since 1893. NOTE Confidence: 0.820135530666667 00:02:01.440 --> 00:02:04.128 And so what you mentioned that the NOTE Confidence: 0.820135530666667 00:02:04.128 --> 00:02:05.740 automation equipment was aging. NOTE Confidence: 0.820135530666667 00:02:05.740 --> 00:02:06.995 What were the specific issues NOTE Confidence: 0.820135530666667 00:02:06.995 --> 00:02:07.748 you were having? NOTE Confidence: 0.820135530666667 00:02:07.750 --> 00:02:09.436 Was its parts, was it downtime, NOTE Confidence: 0.820135530666667 00:02:09.440 --> 00:02:10.730 was it all of the above? NOTE Confidence: 0.820135530666667 00:02:10.730 --> 00:02:12.658 So we had basically all of the above. NOTE Confidence: 0.820135530666667 00:02:12.660 --> 00:02:15.952 We had equipment that was still installed NOTE Confidence: 0.820135530666667 00:02:15.952 --> 00:02:19.600 back in 1959 that was still in service. NOTE Confidence: 0.820135530666667 00:02:19.600 --> 00:02:21.406 You actually see some of that NOTE Confidence: 0.820135530666667 00:02:21.406 --> 00:02:23.323 equipment at the Museum of Science NOTE Confidence: 0.820135530666667 00:02:23.323 --> 00:02:24.948 and Industry here in Chicago. NOTE Confidence: 0.820135530666667 00:02:24.950 --> 00:02:26.486 So we were using that equipment, NOTE Confidence: 0.820135530666667 00:02:26.490 --> 00:02:28.695 still wasn't serviced and then some of NOTE Confidence: 0.820135530666667 00:02:28.695 --> 00:02:31.072 the equipment that was installed in 2004, NOTE Confidence: 0.820135530666667 00:02:31.072 --> 00:02:33.964 we were having a number of NOTE Confidence: 0.820135530666667 00:02:33.964 --> 00:02:36.300 issues with that as well. NOTE Confidence: 0.820135530666667 00:02:36.300 --> 00:02:37.980 Spare parts was definitely a big, NOTE Confidence: 0.820135530666667 00:02:37.980 --> 00:02:39.928 big part of it. NOTE Confidence: 0.820135530666667 00:02:39.930 --> 00:02:42.930 Some of the drives were already NOTE Confidence: 0.820135530666667 00:02:42.930 --> 00:02:45.233 obsolete and finding parts, NOTE Confidence: 0.820135530666667 00:02:45.233 --> 00:02:47.637 finding drives were definitely, NOTE Confidence: 0.820135530666667 00:02:47.640 --> 00:02:49.410 you know, getting harder and harder. NOTE Confidence: 0.820135530666667 00:02:49.410 --> 00:02:51.758 So we had to NOTE Confidence: 0.820135530666667 00:02:51.760 --> 00:02:54.490 find a solution again that will NOTE Confidence: 0.820135530666667 00:02:54.490 --> 00:02:58.040 give us a more reliable system. NOTE Confidence: 0.8270217 00:03:01.470 --> 00:03:02.850 If the mill is down, NOTE Confidence: 0.8270217 00:03:02.850 --> 00:03:04.974 you know the guys upstream breaking NOTE Confidence: 0.8270217 00:03:04.974 --> 00:03:07.878 the rail and getting it ready have to NOTE Confidence: 0.8270217 00:03:07.878 --> 00:03:09.648 stop the guys downstream processing NOTE Confidence: 0.8270217 00:03:09.648 --> 00:03:11.798 the fence post and the other material NOTE Confidence: 0.8270217 00:03:11.798 --> 00:03:14.014 that we make you know don't have NOTE Confidence: 0.8270217 00:03:14.014 --> 00:03:16.261 anything to to process because we are NOTE Confidence: 0.8270217 00:03:16.270 --> 00:03:18.382 basically in about four hours we NOTE Confidence: 0.8270217 00:03:18.382 --> 00:03:21.014 turn a piece of rail into a fence NOTE Confidence: 0.8270217 00:03:21.014 --> 00:03:23.690 post or a tea post or a sign post. NOTE Confidence: 0.8270217 00:03:23.690 --> 00:03:26.106 So we are very lean in that aspect. NOTE Confidence: 0.8270217 00:03:26.110 --> 00:03:29.610 We pretty much roll process paying the NOTE Confidence: 0.8270217 00:03:29.610 --> 00:03:33.250 the product and ship it within a week. NOTE Confidence: 0.8270217 00:03:33.250 --> 00:03:35.476 So if the mill is down, NOTE Confidence: 0.8270217 00:03:35.480 --> 00:03:36.984 you know everybody's down, NOTE Confidence: 0.8270217 00:03:36.984 --> 00:03:37.736 everybody's waiting. NOTE Confidence: 0.8270217 00:03:37.740 --> 00:03:40.620 What solution did you bring to put in place? NOTE Confidence: 0.8270217 00:03:40.620 --> 00:03:44.239 We brought the solution by using Allen NOTE Confidence: 0.8270217 00:03:44.239 --> 00:03:47.359 Bradley drive for our flex drives. NOTE Confidence: 0.8270217 00:03:47.360 --> 00:03:49.312 So as Dave mentioned, NOTE Confidence: 0.8270217 00:03:49.312 --> 00:03:52.240 their existing drive worked very old NOTE Confidence: 0.8270217 00:03:52.329 --> 00:03:55.257 that they were not having capabilities NOTE Confidence: 0.8270217 00:03:55.257 --> 00:03:58.730 to adjust the speed in a dynamic way. NOTE Confidence: 0.8270217 00:03:58.730 --> 00:04:01.243 So the first step was to replace NOTE Confidence: 0.8270217 00:04:01.243 --> 00:04:03.759 these drives with a brand new drives. NOTE Confidence: 0.8270217 00:04:03.760 --> 00:04:05.750 Without touching the the hardware, NOTE Confidence: 0.8270217 00:04:05.750 --> 00:04:07.688 without touching the the the machines. NOTE Confidence: 0.8270217 00:04:07.690 --> 00:04:10.231 Basically once the drives were were NOTE Confidence: 0.8270217 00:04:10.231 --> 00:04:12.736 replaced at the same time we wanted to NOTE Confidence: 0.8270217 00:04:12.736 --> 00:04:15.610 give or so a brand new automation system, NOTE Confidence: 0.8270217 00:04:15.610 --> 00:04:17.815 a control system for the complete mill. NOTE Confidence: 0.8270217 00:04:17.820 --> 00:04:21.786 So we put in ControlLogix PLC NOTE Confidence: 0.8270217 00:04:21.790 --> 00:04:25.990 and with our system to control NOTE Confidence: 0.8270217 00:04:25.990 --> 00:04:29.713 the rolling mill. And above this NOTE Confidence: 0.8270217 00:04:29.713 --> 00:04:32.816 system we installed Stratus server NOTE Confidence: 0.8270217 00:04:32.816 --> 00:04:35.768 with the virtual machines NOTE Confidence: 0.8270217 00:04:35.770 --> 00:04:39.358 by using the team manager software NOTE Confidence: 0.8270217 00:04:39.358 --> 00:04:43.684 suite and FactoryTalk View for the HMI NOTE Confidence: 0.8270217 00:04:43.684 --> 00:04:47.469 screens and the user interfaces and NOTE Confidence: 0.8270217 00:04:47.469 --> 00:04:49.352 what was life like after you had NOTE Confidence: 0.8270217 00:04:49.352 --> 00:04:51.383 this new system in place compared NOTE Confidence: 0.8270217 00:04:51.383 --> 00:04:53.173 to where you were beforehand? NOTE Confidence: 0.8270217 00:04:53.180 --> 00:04:54.896 Well, it was night and day, NOTE Confidence: 0.8270217 00:04:54.900 --> 00:04:57.803 I mean we were able to quickly NOTE Confidence: 0.8270217 00:04:57.803 --> 00:05:00.218 diagnose, you know any issues, NOTE Confidence: 0.8270217 00:05:00.220 --> 00:05:03.640 the ability to go into any of the HMI NOTE Confidence: 0.8270217 00:05:03.640 --> 00:05:06.100 screens through the facility, NOTE Confidence: 0.8270217 00:05:06.100 --> 00:05:07.868 pull up a screen and be able to NOTE Confidence: 0.8270217 00:05:07.868 --> 00:05:09.941 just go in there and find out what NOTE Confidence: 0.8270217 00:05:09.941 --> 00:05:11.730 the problem is from that screen, NOTE Confidence: 0.8270217 00:05:11.730 --> 00:05:13.790 made troubleshooting, you know, NOTE Confidence: 0.8270217 00:05:13.790 --> 00:05:16.672 a completely different, you know, game. NOTE Confidence: 0.8270217 00:05:16.672 --> 00:05:18.016 It simplified, you know, NOTE Confidence: 0.8270217 00:05:18.016 --> 00:05:19.840 the life of my guys in the electrical NOTE Confidence: 0.8270217 00:05:19.892 --> 00:05:21.684 side and even on the mechanical side, NOTE Confidence: 0.8270217 00:05:21.690 --> 00:05:22.780 because they can, you know, NOTE Confidence: 0.8270217 00:05:22.780 --> 00:05:23.722 kind of see NOTE Confidence: 0.8270217 00:05:23.722 --> 00:05:25.292 something's about to happen before NOTE Confidence: 0.8270217 00:05:25.292 --> 00:05:25.920 it happens. NOTE Confidence: 0.8270217 00:05:25.920 --> 00:05:28.160 So they can see it very quickly, NOTE Confidence: 0.8270217 00:05:28.160 --> 00:05:31.301 and we have a screen on the machine shop NOTE Confidence: 0.8270217 00:05:31.301 --> 00:05:34.005 where they can see the mill is down. NOTE Confidence: 0.8270217 00:05:34.010 --> 00:05:35.540 And they no longer have to wait for the call, NOTE Confidence: 0.8270217 00:05:35.540 --> 00:05:36.986 they they already start heading out. NOTE Confidence: 0.8270217 00:05:36.990 --> 00:05:38.964 So it it has been basically a NOTE Confidence: 0.8270217 00:05:38.964 --> 00:05:41.017 game changer for us to be able NOTE Confidence: 0.8270217 00:05:41.017 --> 00:05:42.447 to have all these equipment. NOTE Confidence: 0.8270217 00:05:42.450 --> 00:05:43.950 I'm so happy to hear that. NOTE Confidence: 0.8270217 00:05:43.950 --> 00:05:44.428 And Antonio, NOTE Confidence: 0.8270217 00:05:44.428 --> 00:05:46.340 I know AIC is a member of the NOTE Confidence: 0.8270217 00:05:46.399 --> 00:05:48.447 Rockwell Automation Partner Network. NOTE Confidence: 0.8270217 00:05:48.450 --> 00:05:50.082 We're very grateful to have companies NOTE Confidence: 0.8270217 00:05:50.082 --> 00:05:52.509 like you that know how to pick and place NOTE Confidence: 0.8270217 00:05:52.509 --> 00:05:54.290 these different parts and build a system. NOTE Confidence: 0.8270217 00:05:54.290 --> 00:05:56.243 Do you have any advice or any NOTE Confidence: 0.8270217 00:05:56.243 --> 00:05:58.048 thoughts for other companies that NOTE Confidence: 0.8270217 00:05:58.048 --> 00:05:59.868 are facing aging infrastructure, NOTE Confidence: 0.8270217 00:05:59.870 --> 00:06:01.826 not really sure how to start? NOTE Confidence: 0.8270217 00:06:01.830 --> 00:06:04.210 There are a lot of positive aspects NOTE Confidence: 0.8270217 00:06:04.210 --> 00:06:06.240 in using Allen Bradley NOTE Confidence: 0.8270217 00:06:06.240 --> 00:06:08.270 products which like the first NOTE Confidence: 0.761273577058824 00:06:08.351 --> 00:06:10.759 point I would put in the network. NOTE Confidence: 0.761273577058824 00:06:10.760 --> 00:06:14.440 Having everything integrated in NOTE Confidence: 0.761273577058824 00:06:14.440 --> 00:06:17.866 single system is, there's definitely a NOTE Confidence: 0.761273577058824 00:06:17.866 --> 00:06:21.418 positive point from from what I think. NOTE Confidence: 0.761273577058824 00:06:21.420 --> 00:06:24.297 So I would say like all these NOTE Confidence: 0.761273577058824 00:06:24.297 --> 00:06:26.924 companies that they are looking to NOTE Confidence: 0.761273577058824 00:06:26.924 --> 00:06:29.976 have a unique system like where every NOTE Confidence: 0.761273577058824 00:06:30.063 --> 00:06:32.996 single piece on the network can be NOTE Confidence: 0.761273577058824 00:06:33.000 --> 00:06:36.304 giving diagnosis, diagnosed and NOTE Confidence: 0.761273577058824 00:06:36.304 --> 00:06:39.608 informations about the process, NOTE Confidence: 0.761273577058824 00:06:39.610 --> 00:06:42.850 it's definitely a point to look at and a NOTE Confidence: 0.761273577058824 00:06:42.850 --> 00:06:45.569 positive point for the for the solution. NOTE Confidence: 0.761273577058824 00:06:45.570 --> 00:06:48.441 I have to say that I took over the NOTE Confidence: 0.761273577058824 00:06:48.441 --> 00:06:50.727 electrical side of things months, just a NOTE Confidence: 0.761273577058824 00:06:50.727 --> 00:06:53.210 couple of months before I met you know, NOTE Confidence: 0.761273577058824 00:06:53.210 --> 00:06:57.280 AIC for the second time. NOTE Confidence: 0.790330217857143 00:06:59.830 --> 00:07:02.245 The equipment, the Rockwell equipment NOTE Confidence: 0.790330217857143 00:07:02.245 --> 00:07:05.376 was basically allow me to learn on NOTE Confidence: 0.790330217857143 00:07:05.376 --> 00:07:07.835 the fly as we were installing the NOTE Confidence: 0.790330217857143 00:07:07.835 --> 00:07:10.140 equipment and I'm coming from the NOTE Confidence: 0.790330217857143 00:07:10.140 --> 00:07:12.588 mechanical side to the electrical side. NOTE Confidence: 0.790330217857143 00:07:12.590 --> 00:07:14.370 It made it very easy for me to be able NOTE Confidence: 0.790330217857143 00:07:14.424 --> 00:07:16.224 to make that transition at the same time NOTE Confidence: 0.790330217857143 00:07:16.224 --> 00:07:18.506 that we were making this whole, you know, NOTE Confidence: 0.790330217857143 00:07:18.506 --> 00:07:20.246 automation upgrade and their facility. NOTE Confidence: 0.790330217857143 00:07:20.250 --> 00:07:23.190 So, definitely a time to to be able to go NOTE Confidence: 0.790330217857143 00:07:23.266 --> 00:07:25.570 look back and say, yeah, you know, it was, NOTE Confidence: 0.790330217857143 00:07:25.570 --> 00:07:28.366 it was definitely a challenging project, NOTE Confidence: 0.790330217857143 00:07:28.370 --> 00:07:29.694 but very successful. NOTE Confidence: 0.790330217857143 00:07:29.694 --> 00:07:31.254 You know, nonetheless so excellent. NOTE Confidence: 0.790330217857143 00:07:31.254 --> 00:07:34.039 Well, how nice to have both of you in here, NOTE Confidence: 0.790330217857143 00:07:34.040 --> 00:07:35.874 kind of both sides of this story. NOTE Confidence: 0.790330217857143 00:07:35.880 --> 00:07:37.698 Thank you both for joining me. NOTE Confidence: 0.790330217857143 00:07:37.700 --> 00:07:38.190 Thank you. NOTE Confidence: 0.790330217857143 00:07:38.190 --> 00:07:39.660 You're welcome and thanks so much NOTE Confidence: 0.790330217857143 00:07:39.660 --> 00:07:40.680 for sharing your story. NOTE Confidence: 0.790330217857143 00:07:40.680 --> 00:07:42.346 I look forward to hearing more success NOTE Confidence: 0.790330217857143 00:07:42.346 --> 00:07:43.901 coming out of Chicago Heights Steel NOTE Confidence: 0.790330217857143 00:07:43.901 --> 00:07:45.756 and I thank you for the opportunity. NOTE Confidence: 0.790330217857143 00:07:45.760 --> 00:07:46.480 Thank you.