DETROIT, April 11 /PRNewswire/ -- Henkel today announced that its
SmartControl advanced personal computer (PC) based process control systems
have the potential to help paint and coatings plants reduce material usage 5
to 20 percent, while increasing efficiency up to 10 percent and lowering
defect costs between 2 to 5 percent.
    The Crown Group, one of Henkel's SmartControl development partners and an
early adopter of the technology, recently reported similar successful results.
The SmartControl system was initially installed two years ago at The Crown
Group's Shelby Township, Mich. facility, controlling the plant's 12-stage
phosphating process.
    "Our experience with SmartControl was positive right from the start," said
Ron Haught, The Crown Group's Shelby Township facility/system manager.  "Our
OEM customers produce some of the top luxury brands in the industry, which
require reliable quality.  This system helps us consistently meet those
requirements."
    Henkel's SC 1000 SmartControl and SC 2000 SmartControl series of process
controllers can be easily customized to fit the needs of individual paint and
coatings lines as well as other manufacturing operations.  The SC 1000 model
handles all pretreatment, electrocoat paint and waste treatment product feed
and controls.  The SC 2000 model handles those requirements as well as motor
controls necessary to completely run most paint lines.  The SC 3000 model
handles the same functions as the SC 1000/2000 models, in addition to
providing network connected Auto-Titration analysis.
    Unlike traditional programmable logic controller (PLC) or solid-state
process control systems, SmartControl is based on a standard PC powered by
Henkel's proprietary control algorithms, developed over decades of providing
surface treatment and coatings expertise.  In contrast to other control
systems, SmartControl uses these sophisticated algorithms to process input
from separate manufacturing stages, interpret the data and make decisions and
necessary corrections to the line.  The end result is technology that delivers
repeatable quality and addresses unpredictable challenges in crucial coatings
processes.
    "SmartControl technology is valued by customers for its ability to ensure
processes remain within specifications, preventing costly manufacturing
interruptions," said Steven Moore, Henkel business director.  "As factory
paint and coating lines grow older and require new process control systems,
SmartControl is a cost effective option for the next generation of
manufacturing plants."
    SmartControl systems cost about 10 to 30 percent less than solid-state or
PLC based systems.  Unlike these traditional systems, it can be quickly
expanded to include more workstations and is easy to update and enhance
through new software.

    How SmartControl works:
    The SmartControl process control system uses a series of compact remote
process input/output (I/O) panels located at coatings or surface treatment
stages within a plant.  In most cases, one panel can handle two process
stages.  These versatile panels keep costs low by reducing the need for
additional wiring and conduits.  All input devices, such as sensors measuring
conductivity, temperature and pH levels, are connected to a remote process I/O
panel.  The chemical pumps are connected to a central chemical feed panel.
    SmartControl links all these devices through common protocols including
Ethernet and Profibus DP, and can work within most existing plant data
communication systems.  This translates into a much lower investment in
equipment to link monitoring technology.
    The SmartControl detailed onscreen displays enable operators to quickly
monitor and control all process variables -- including trend charts -- along
with control events such as alarms, set-point changes (SPC) and current
operating modes using precise, real-time information on plant operations.  In
addition to this, the system provides SPC charts for all monitoring variables,
with automatically calculated upper and lower control limits, Cp and Cpk
values.  Cp measures how wide the spread of process control variables have
been over a period of time.  Cpk calculations demonstrate how well centered
control is within the spread of measurements.
    Operators can enter manually collected readings from titrations, spray
pressures and production and use information from these readings to remotely
set or adjust controls for each machine to achieve optimum manufacturing
quality and efficiency.
    "SmartControl is designed to optimize highly automated paint and coatings
lines, without being complicated to use," said Moore.  "While this technology
is extremely sophisticated, it is also very reliable, effective and simple for
plant employees to operate."

    Henkel is the market leader in adhesives, sealants and surface treatments
to the transportation industry.  Backed by extensive design capabilities, a
broad product range, specific application knowledge and technical expertise,
the company delivers solutions to all segments of automotive development --
automotive body, interior, chassis, electronics and powertrain production.
Through powerful brands like Autophoretic(R), Bonderite(R), Frekote(R),
Loctite(R) and Multan(TM), Henkel provides significant economic and
environmental advantages for today's vehicles, making them safer, more
comfortable and extending vehicle value.
    The Henkel Group operates in three strategic business areas: Home Care;
Personal Care; and Adhesives, Sealants and Surface Treatments.  The automotive
group is an integral part of the Adhesives, Sealants and Surface Treatments
business sector, which also serves the transportation, electronics, aerospace,
metal, durable goods, consumer goods, maintenance and repair and packaging
industries, and offers a broad range of products for the craftsman and
consumer.  With brands and advanced technologies, Henkel makes people's lives
easier, better, and more beautiful.  50,000 employees work for the Henkel
Group worldwide.  People in 125 countries around the world trust in brands and
technologies from Henkel - "A Brand like a Friend."

Link to this page: