Case Study: Rapid Coil Cart Replacement
Key Outcomes
- Coil slitting line restored in 10 hours
- Production resumed for second shift
- Mechanical, electrical, and controls support delivered through one integrated team
- Reduced coordination delays and accelerated startup
- Minimized downtime and production impact
The Challenge
A coil slitting manufacturer experienced a complete failure of a critical coil cart, bringing production to an immediate stop. Without the cart operating, material could not move through the line and production could not continue.
With downtime increasing by the minute, the customer needed more than labor support. They needed a team capable of coordinating the mechanical, electrical, and controls work required to remove the failed equipment, install the replacement, and return the line to service as quickly as possible.
Our Solution
ABCO South, The Automation Group, and FABCO mobilized a coordinated in-house response to support the replacement effort. Electricians, controls engineers, millwrights, and support personnel worked together as a single team to remove the failed coil cart, install the replacement unit, complete electrical integration, update controls as required, and commission the system.
Because the work was supported internally across multiple disciplines, activities that would normally require several contractors and separate schedules were completed in parallel. Mechanical installation, electrical work, controls support, and startup efforts were coordinated together to reduce delays and accelerate recovery.
This integrated approach allowed the customer to move from equipment failure to production startup in a fraction of the time a traditional replacement effort would typically require.
The Outcome
Within 10 hours of beginning work, the replacement coil cart was installed and operational. The customer resumed production in time for second shift, dramatically reducing downtime and limiting disruption to plant operations.
By leveraging ABCO South and FABCO’s combined in‑house capabilities, the customer avoided an extended outage and returned to normal production significantly faster than would have been possible relying on internal resources alone.
Case Study: Conveyor Retrofit Supports New Line Installation and Improves Safety
Key Outcomes
- Existing conveyor retrofitted instead of replaced
- Machine successfully relocated into a smaller footprint
- Controls and sensors updated to maintain process performance
- Improved operator access and emergency egress
- Supported production expansion while meeting safety guidelines
Our Solution
ABCO South Automation Group evaluated the existing conveyor system and completed a retrofit to fit the updated layout requirements. Our team shortened the conveyor and modified the controls and sensor systems to maintain the intended process flow and machine operation.
The retrofit was designed to preserve production performance while adapting the equipment to safely operate within the available floor space.
The Challenge
A medical device manufacturer was preparing to install new production lines and needed to relocate an existing machine into a smaller area of the facility. During planning, it became clear that the existing finished-part conveyor was too long for the new space and reduced operator access around the machine.
In its original configuration, the layout did not provide adequate exit access for operators to move out of the area quickly in the event of an emergency, creating a safety concern and limiting the ability to run the equipment in the new location.
The Outcome
The customer was able to successfully relocate and operate the machine in its new location while maintaining proper operator access and aligning with facility safety requirements.
By modifying and reusing existing equipment instead of replacing the entire conveyor system, the customer reduced disruption, supported their production expansion plans, and created a safer operating environment.