Ceramics Press Downtime Reduction

Problem: A client in the ceramics industry was experiencing frequent downtime on a critical production press, creating a major bottleneck. One key cause was that the operators could not diagnose or troubleshoot PLC alarms without a laptop, meaning the press often sat idle waiting for maintenance, even for simple issues.

Solution: PTS evaluated the operation through interviews with operators, engineers, and maintenance staff. We identified that the existing press HMI only offered basic pushbuttons and a selector switch, with no visual PLC status or alarm information.

We replaced the existing interface with a 10” Maple Systems touchscreen HMI integrated with the existing Allen-Bradley PLC. The new HMI retained all previous operator controls while adding:

• Real-time status indication and alarm descriptions
• Maintenance troubleshooting screens
• A recipe management system for quick product changeovers
• Remote PLC access via an eWon WiFi router for off-site support

PTS handled the entire scope:

• Full electrical drawing set (panel layout, wiring diagrams, bill of materials)
• PLC and HMI programming
• Design and assembly of a Hoffman swivel-mounted HMI enclosure for operator convenience
• Enclosure assembly and wiring
• On-site installation support and startup testing

Results: The upgrade empowered operators to resolve issues on the spot, reduced reliance on laptops and maintenance personnel for troubleshooting, and significantly cut unplanned downtime—improving the press’s overall equipment effectiveness (OEE).