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Project Gallery | Manufacturing
Every project has a unique set of challenges and objectives, including scope, budget, time frame, regulatory requirements and more. MAVERICK addresses each concern in developing custom solutions that meet each client's needs. We offer extensive services and expertise in a range of industries. Learn more …
Completed Projects
- Modicon PLC Upgrade
MAVERICK upgraded a client’s control system with the latest Modicon Quantum processors and communication modules in order to support Ethernet communications. The new solution is easily upgradeable, scalable and supports a future enterprise software integration project.
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- Manufacturer of Currency Paper Integrates Vision Inspection System to Ensure 100% Consistent Quality
A manufacturer of high-quality paper sought a vision inspection system that would ensure their U.S. currency paper consistently satisfied federal government standards. The speed, accuracy and 100% reliability of this system were essential.
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- MAVERICK Technologies to Implement Data Matrix Cap Verification System for Healthcare Products Manufacturer
MAVERICK Technologies announced today that it has won a two-dimensional data matrix cap verification project for a global manufacturer in the healthcare industry. The project scope includes definition, design, programming, procurement and startup support services, including PLC and HMI development, factory acceptance testing and site acceptance testing. The data matrix verification system comprises two steps. First, a conveyor will transport vials of up to 100 milliliters past two printers that will label the vial cap with a lot number. The first printer will print the six-digit number on the side of the crimped cap, and the second printer will print a two-dimensional data matrix coded version of the same lot number on the top of the cap. Then immediately after printing, a vision system will inspect the two-dimensional code and determine its readability and accuracy. Vials with poorly printed or inaccurate codes will be rejected from the conveyor. A downstream accumulation table will collect the remaining good vials. site acceptance testing.
- MAVERICK Technologies Wins Wonderware Information Server Configuration Project
MAVERICK Technologies announced today that it will begin work on configuring the Wonderware Information Server for a building products manufacturer. The project scope includes specifying the correct computer, setting up the Microsoft operating system, installing the Wonderware software and verifying that the correct license is installed. MAVERICK will also configure the overview screen, migrate the existing InTouch graphics and configure the ActiveFactory tools, allowing the client to view the process via the Internet.
- Airline Manufacturer Improves Accuracy of Testing with New Touch Probe Certification System
The project goal was to design and build a three-axis test system for recertifying touch probes used in the production and assembly of airplane parts and assemblies. The touch probes are ultra-accurate, ruby-tipped sensors used to verify machining and assembly tolerances on all aircraft to .0001 inch. The yearly recertification of the probes is required to meet current Federal Aviation Administration (FAA) specifications, and the OEMs do not provide secondary testing or recertification services.
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- Reporting System Implemented to Increase Efficiency
MAVERICK provided a fiberglass manufacturer with a reporting system for its plant. Specifically, MAVERICK used interfaces between two SLC 504s and a Foxboro AW70 through RSLINX. Several operating screens showing the flexible and rod line systems were created. Using data for Windows and Fox history, the Foxboro system was interfaced with Microsoft Visual Basic. Information in Visual Basic was then generated into shift and daily reports. Northern Analytical SPC software was interfaced with Visual Basic and used for generating graphs from the collected data. MAVERICK engineering services delivered a successful reporting system which met the client's functional requirements. The reporting system provided the manufacturer with the tools to increase efficiency throughout the plant.
- SCADA System for a Glass Rod Manufacturer
In implementing this SCADA system for glass rod manufacturing, MAVERICK performed data acquisitions to collect data from the Allen-Bradley SLC 500 PLCs into a Foxboro DCS. Custom VB scripting was utilized to move historical data within the Fosboro SPC module.
- Textile Finishing Plant
MAVERICK Technologies provided DeltaV programming and application development for the tentor frame and prep range areas of this textiles facility. Project specifics included fieldbus technology, ASi Bus, bi-directional serial interface (Modbus) to Allen-Bradley PLC, hardwired I/O, I-Fix graphics, advanced temperature control algorithms, MS Access database VB programming with OPC, commissioning and startup.
- 3B3BX Project — X-Ray Film Coater
Project consisted of integrating two Coater Drives together with Siemens S5 PLC. Project included over 1000 I/O. Statement list and ladder logic were used to develop the code. The Siemens PLC interfaced with Dupont’s Bailey DCS.
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- Dupont Technologies Transfer (Multiple Applications)
Project consisted of developing code and applications to test various Fiber Machines. Application was initially developed and tested in an Allen-Bradley PLC-5. Upon completion of the testing, the logic was converted to a Siemens S5 (135U) PLC. Statement lists were exclusively used in the development.
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- Process and Building Safety Systems Upgrade
Project consisted of developing Siemens S7, Siemens 505 and Triconex control code for the Process and Building Safety Systems. Developed re-usable code libraries for Siemens S7 (ES-Tools), Siemens 505 (APT) and Triconex (Tristation 1131). MAVERICK continues to provide ongoing work for this facility.
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- Sand Core for Casting Pipe
Project consisted of Siemens S5 programming for the process equipment. Project included over 10 remote racks and 700 I/O. Statement lists and ladder logic were used to develop the code.
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- Control System Upgrade
MAVERICK replaced a client’s existing control system with a Siemens Moore APACS DCS following a quality assurance program to satisfy FDA guidelines, utilizing 4Mation and the ProcessSuite HMI system. The scope of work included the creation and / or modification of detailed design drawings, configuration of approximately 125 I/O data points, system control, process alarms and interlocks, and the development of graphic displays to provide operators with an interface to the system, internal staging, customer acceptance testing, checkout / startup and installation of the APACS system.
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- Documentation and Control System Configuration
One recent MAVERICK project required comprehensive engineering design services to “reverse engineer” the complete electrical, instrumentation and control system documentation for the client’s facility, including a Siemens Moore APACS DCS, Allen-Bradley and Siemens PLCs, and Wonderware HMI terminals. MAVERICK reviewed the existing documentation for accuracy and then modified and created additional drawings and / or design documentation to improve and support the reliability, operation and maintenance of the system. The entire control system configuration, containing approximately 2,000 I/O points, was defined by logic diagrams, cause-and-effect matrices and narrative description. The existing APACS and HMI configuration was reviewed for conformance to logic diagrams and complex loop definitions.
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- Design and Documentation for New DCS
MAVERICK was recently involved in the design phase of a plant automation project in which a Siemens Moore APACS DCS was installed. The project scope included updating the P&IDs with CAD-generated drawings through field verification, including all DCS symbology. A complete instrument index with I/O listing was generated.
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- Design Engineering for Plant Automation Project
This project required design engineering, including modifications to the P&IDs, a preliminary I/O list and a complete detailed design and construction package for a plant automation project. The electrical design package included I/O drawings showing the complete routing between the APACS DCS I/O modules and the field devices for approximately 600 I/O points, approximately 400 loop drawings, junction box and panel wiring diagrams, instrument location drawings, conduit and cable routing plans, and conduit and cable schedules.
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- Complete Control System Recode
MAVERICK recently performed a complete control system recode, utilizing an existing Siemens Moore APACS DCS combined with modifications to the systems architecture. MAVERICK also verified and corrected the supporting design documentation, including P&IDs, I/O listing and termination drawings. The project required a fully documented configuration, per current good manufacturing practices (cGMP), that could then be validated for FDA compliance. The new configuration was performed using a detailed control system specification and current APACS system design standards. The project included 1,200 I/Os and the development of 45 detailed process graphics, dozens of supporting graphics and approximately 2,500 tags using Wonderware FactorySuite 7.1. The configuration was subjected to documented testing, as the system was internally staged, was customer-witnessed factory acceptance tested (FAT) and was site acceptance tested (SAT), to assure compliance to specification.
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- Complete Control System Recode
The project included a complete control system recode, utilizing an existing Siemens Moore APACS DCS. The project required a fully documented configuration per current good manufacturing practices (cGMP) that can then be validated for FDA compliance. This recode was for one of three existing plants in the facility consisting of 750 I/Os. The new configuration was performed using a detailed control system specification and current system design standards on an extremely aggressive schedule. The project also included reconstructing 40 detailed process graphics, dozens of supporting graphics and approximately 2,000 I/O tags using Wonderware FactorySuite 7.1. In accordance with MAVERICK’s quality standards, the configuration was subjected to significant documented testing, as the system was internally staged, was customer-witness factory acceptance tested (FAT) and was site acceptance tested (SAT), to assure compliance to specification.
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- Control System Enhancements for Improved Reliability
MAVERICK has participated in several projects and numerous site support trips to assist a client’s facility with its control systems, which include a Siemens Moore APACS DCS, Allen-Bradley PLCs and a Wonderware HMI. This facility has been undergoing process enhancements for two years in order to achieve a higher reliability factor. These enhancements have been performed both offline during plant shutdowns and during full operation. The systems have approximately 2,000 I/Os with about 7,000 WW database tags.
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- Control System Design and Configuration
For one client with three sites, MAVERICK utilized several control systems: Siemens Moore Quadlog Safety PLCs for emergency shutdown applications, Modicon Quantum PLCs for the basic process control system as well as substation automation applications, and a single Allen-Bradley PLC for substation automation. The new systems were interfaced to various existing equipment, including Omni flow computers with control and energy management systems (Honeywell TDC3000 and Bailey Infi90) at each of the three client sites. The control system design and configuration consisted of approximately 540 field I/Os across the three sites. The initial scope included the verification and correction of existing P&IDs and the completion of a construction design package, including an I/O list, location plans, instrument specifications, wiring and connection diagrams, loop sheets and a construction specification.
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- Subcontractor for System I&C at Wafer Fabrication Facility
Working as a subcontractor, MAVERICK Technologies helped one of the largest 300mm semiconductor wafer fabrication facilities in the world implement a zero-incident system. The project scope included work on the central utilities plant, the exhaust scrubber yard, the environment system (temperature, humidity, pressure and airvelocity control) and the hazardous production material (HPM) / life safety and security (LSS) systems. The HPM / LSS system is a triple redundant system capable of monitoring chemicals, gases and hazardous production materials. MAVERICK completed a turn-key I&C design, programming and installation for the facility and LSS systems, which included Siemens PLCs, Triconex TMRs and Intellution HMI. This fab has utilized MAVERICK engineers, technicians, technical writers, QA / QC, Maximo support technicians and designers in sustaining activities for more than five years.
- Subcontractor for Facilities Management Systems at Wafer Fabrication Facility
Working as a subcontractor under an extremely tight deadline, MAVERICK Technologies provided all the facilities management systems for a new 300mm semiconductor wafer fabrication facility. The facility had to be integrated into an expanded CUB and is a key contributor in meeting demand for processor manufacturing. The contract required MAVERICK to complete an electrical design and software integration of a large Allen-Bradley PLC and HMI. MAVERICK had to coordinate with multiple trades and simulate software to ensure flawless integration with cutting over new software into an existing CUB PLC system. The project also included extensive backup plans in case any unforeseen issues arose.
- Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its 200mm Wafer Fabrication Facility
This leader in wafer technology and innovation needed a cost-effective FMCS to address issues of compliance, safety, constructability, system uptime, operability and maintenance.
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- MAVERICK Technologies Troubleshoots Control Problems at Semiconductor Manufacturing Plant
MAVERICK Technologies announced today that it recently helped a power semiconductor manufacturer fix several control system problems. The plant contacted MAVERICK when it experienced operational problems with its air handling unit and chiller pneumatic controls because one of its valves did not open. MAVERICK performed troubleshooting on the PLC and HMI controls to restore correct operation, and it also relocated the humidity / temperature sensor to provide more accurate monitoring.
- Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its Wafer Fabrication Facility — Phase 2
The client required the design and installation of an FMCS to provide continuous monitoring and control of the cleanroom environment, utilities plant and life safety system for the DMOS5 semiconductor wafer fabrication facility.
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- Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its Wafer Fabrication Facility — R&D1 Phase 2
The client required system updates to double the number of tools and gas cabinets.
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- Semiconductor Manufacturer Implements Facility Monitoring and Control System (FMCS)
The client required the design and installation of an FMCS to provide continuous monitoring and control of the cleanroom environment, utilities plant and support areas for its wafer fabrication facility.
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- Semiconductor Manufacturer Implements Life Safety System
The client required the design and installation of a life safety system (LSS) to reliably monitor safety conditions in the facility.
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- Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its Wafer Fabrication Facility — R&D1 Phase 1
A client required the design and installation of an FMCS to provide continuous monitoring and control for its R&D1 semiconductor wafer fabrication facility.
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- Wafer Fabricator Achieves Continuous Monitoring and Control of Cleanroom Environment
The client wanted a solution to continuously monitor and control the cleanroom environment, utilities plant and support areas.
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- GRI Fermentation Decontamination System at Pharmaceutical Company
At one major pharmaceutical company, the decontamination system uses software to control the decontamination of the waste produced while growing cells. The waste is cooled and pumped to the sewer, and the tank is then flushed with water. Both decontamination tanks can run at the same time, and the lead tank usage is automatically swapped to share runtime. MAVERICK has written the PLC logic running on the single Allen-Bradley SLC 5/04 processor. Both analog and digital I/Os monitor temperatures, pressures and levels while controlling valves, pumps and agitators. The SCADA system consists of an IBM-compatible computer operating Wonderware version 5 software. MAVERICK configured the LAN connection to the facility's Oracle database for batch information storage and wrote special Visual Basic routines for operator interaction with SQL database.
- Pharmaceutical Production Building Retrofit
MAVERICK Technologies provided instrument, electrical, and mechanical engineering and design services. Initially, MAVERICK was responsible for working with Corporate Engineering in developing the preliminary design for the project that is an automatic nitrogen blanketing and purge system for the process equipment in the pharmaceutical chemical plant. Subsequently, MAVERICK was awarded the final design contract and worked closely with the client to develop instrument, electrical, and mechanical purchasing and installation packages for the new process equipment and their associated controls. All new instrumentation and mechanical piping / valving was specified and designed in detail using the latest available database and CAD technologies. The interfaced controls include both DCS and PLC hardware. MAVERICK is also providing engineering design for the additional upgrade of all process controls in the building. This was a controls retrofit to a 25-year-old process facility using the newest state-of-the-art controls offered by Emerson.
- Pharmaceutical Manufacturing Facility Requires Fast-Track
Construction and Production with 100% FDA Compliance
A manufacturer of high-quality pharmaceutical eyewash solutions needed to establish new
systems to ensure consistent satisfaction of Food and Drug Administration (FDA ) standards.
The speed, accuracy and 100% reliability of these systems are essential.
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- Encapsulation Project for Pharmaceutical Company
As part of one company’s validation protocol preparation and execution project, MAVERICK installed and integrated RSView, five Allen-Bradley PLC-5 controllers and Oracle Enterprise 8.
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- Allen-Bradley PLC Support and Modifications for Pharmaceutical Company
As part of one pharmaceutical company’s validation protocol preparation and execution process, MAVERICK installed an Allen-Bradley SLC system and PanelView.
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- Ethanol Tank System for Pharmaceutical Company
As part of one pharmaceutical company’s validation protocol preparation and execution process, MAVERICK installed an Allen-Bradley SLC 5/04 system and RSView.
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- Controls for Pharmaceutical Company
MAVERICK assisted with the validation protocol preparation and execution of a GRI fermentation decontamination system, GRI fermentation bottle reactors and GRI
fermentation cell culture reactor. This project required the installation and integration of five Allen-Bradley SLC 5/04 systems, Wonderware products and an
Oracle interface.
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- Aerosol Suite for Pharmaceutical Company
MAVERICK assisted with this pharmaceutical company’s validation protocol preparation and execution project, which included programming an Allen-Bradley SLC
system and a hardwired Bailey Infi 90 interface.
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- Fermentation Suite Upgrade for Pharmaceutical Company
MAVERICK programmed an Allen-Bradley SLC 5/04 system, PanelView and Wonderware products as part of this pharmaceutical company’s validation protocol
preparation and execution project.
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- Sterile Fill, Building 300 Plasma Filling and IGIV Project PLC Programming for Pharmaceutical Company
As part of this validation protocol preparation and execution project, MAVERICK programmed an Allen-Bradley PLC 5/40 system and ABB DCS interface and provided
ongoing PLC programming support.
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- Plant-Wide Utilities Monitoring and Control System
MAVERICK provided complete engineering and construction services to fully integrate a Foxboro I/A DCS and three sets of redundant Allen-Bradley PLC-5/40
controllers into a new, plant-wide utilities monitoring and control system. Phase I of the automation upgrade began in autumn of 1994 and involved the
installation of a new Foxboro I/A operator console system in a renovated utilities control room. The Foxboro node bus interfaces with the Allen-Bradley Data
Highway Plus via Integrator 30 technology. The project included the control room and fire system monitoring, a cooling tower, instrument air compressors and
dryers, process blowers, multiple chillers, process waste lift and storage areas, and various distributed purified water monitoring points.
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- MAVERICK Technologies Provides Ongoing Alpha System and Programming Tech Support
MAVERICK Technologies announced today that it has won a continuation of its staffing
service contract to support various ongoing engineering needs at a paper mill.
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- Demineralizer Controls Upgrade Project
MAVERICK recently provided a paper mill with the Foxboro I/A systems configuration for a boiler feedwater demineralizer controls upgrade project.
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- Installation and Configuration of Foxboro I/A System
In a recent project at a large paper mill, MAVERICK was responsible for the installation and configuration of the Foxboro I/A system interfaced with a GE Mark V turbine control system. During initial stages of the project, MAVERICK laid out the Foxboro I/A cards and supervised the building of the control cabinet. The cabinet and operating system were shipped to MAVERICK for configuration, and a Mark V simulator was used for configuration purposes. A communication system between the two systems was set up to allow an easier checkout. MAVERICK was also responsible for a cooling water control system, which was configured to utilize the Foxboro I/A, as well. This allowed the Foxboro to not only be a monitor and control for the new turbine, but also for the two cooling towers. Mill representatives visited MAVERICK facilities and performed a thorough checkout, ensuring a smooth startup. After completion of startup, MAVERICK created a performance test data collector by interfacing Microsoft Excel with Foxboro I/A using data for Windows. This provided initial performance data for the new turbine generator system.
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- Major Controls Retrofit
MAVERICK has completed a major controls retrofit for a large paper mill. In a series of consecutive projects, MAVERICK completed conversion to Foxboro I/A / A-B PLC, the Nos. 21, 22, 23 and 24 coated paper machines. The project included ABB paper machine controls through the Foxboro I/A Series 50 DCS with redundant control processors. The new distributed control system interfaced to existing Allen-Bradley Series 5 and GE Series 70 PLCs, with an approximate point count of 600 analog and 550 discrete. The new control system included the size presses, coating kitchen, and stock and broke systems.
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- Controls for Pulp Mill Screens and Paper Machine Cleaners
MAVERICK completed a controls project for the pulp mill screens and paper machine cleaners for a large pulp and paper manufacturer. The project utilized a Bailey Infi-90 DCS and a Wonderware HMI.
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- Upgrades to Rapid Drain and Black Liquor Diversion Control Systems
MAVERICK completed an engineering project to upgrade the rapid drain and black liquor diversion control systems on three recovery boilers. A two-step ESP system was implemented as part of the design. The new control system employed Allen-Bradley PLC-5/25, Wonderware MMI, 8 graphics and 130 I/O points, and monitored operation of the recovery boilers during emergency shutdown procedure and rapid drain.
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Demineralizer System Retrofit for a Paper Company
MAVERICK helped this company convert from its GE 90/70 PLC and Microtie HMI to RSView and a ControlLogix PLC using Ethernet and ControlNet.
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Coated Board Machine Retrofit for a Paper Company
This company wanted to convert from its old bench board, relay controls and older vintage Allen-Bradley PLCs. MAVERICK assisted by implementing a Bailey Net90 DCS (analog), Allen-Bradley PLC-5 (discrete) and DCS to PLC interfaces. MAVERICK provided complete design engineering, installation and startup services.
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400 / 620 TPD OCC for a Paper Company
In this greenfield facility, MAVERICK implemented a Bailey Infi-90 DCS (analog), an Allen-Bradley PLC-5 (discrete), DCS to PLC interfaces and advanced control strategies.
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NC4 and NC5 Fine Paper Machines Retrofit for a Paper Company
This company wanted to convert from its bench board, relay logic and various older PLCs. MAVERICK implemented a Bailey Infi-90 DCS (analog), Allen-Bradley PLC 5/60 (discrete), DCS to PLC interfaces, Measurex MX open interface and Allen-Bradley drives interface. MAVERICK was responsible for all control logic, SAMA diagrams, programming, HMI development and startup services.
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Coated Machines (21, 22, 23 & 24) Retrofit for a Paper Company
MAVERICK implemented a Foxboro I/A system, Allen-Bradley PLC and DCS to PLC interface. MAVERICK technicians provided complete startup services.
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Groundwood Mill Retrofit for a Paper Company
This project involved an Allen-Bradley PLC 5/80 connected to 900 field I/Os, an Allen-Bradley coprocessor running a custom C program and seven networked Wonderware nodes on Ethernet. The controls consisted of 70 PID loops using PLC functions (many cascaded) and 120 Wonderware graphics. The script was embedded within graphics to allow modification of the rate and load grinding algorithms. A custom Modbus interface was also created to the Westinghouse WDPF highway via a PC for operation and performance monitoring of the groundwood mill and power generators. Finally, the control system for the mill wastewater treatment plant incorporated an Allen-Bradley PLC 5/40 with 350 field I/Os and five networked Wonderware nodes with 30 graphics.
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BMS Retrofits for Multiple Clients
Allen-Bradley PLCs (PLC 5) have been utilized for burner management system controls and DCS interface for the combustion controls of more than 25 boilers within the pulp and paper industry. MAVERICK has been responsible for working with insurance carriers to ensure that the proper recommended requirements are followed (NFPA, BLRBAC, NEC, etc.). Several conversions from various PLC systems, bench boards and relay systems have been performed.
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Off-Machine Coater
MAVERICK Technologies provided DeltaV programming, screen development, commissioning and startup for an off-machine specialty paper coater application.
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Paper Sizing Application
Project consisted of developing Siemens S5 (115U) batch code for a Homogenization and Emulsification paper sizing application. Statement lists, Control Systems Flow Charts, and ladder logic were all used to develop the code. Project included over 1000 I/O for three (3) PLCs.
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