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Case Study

A B Graphic International Ltd

The customer requirements

A B Graphic International Ltd (ABG) originally engaged PP to design and manufacture the electrical back plates on its new Digicon 3 digital print finishing machine and delivering them to the ABG facility in Bridlington, where the cables and harnesses would then be fitted.

However, during the design engineering discussions, it quickly became apparent that a more value-added design would be beneficial, allowing for a modular, configurable and pre-wired (Plug & play) style solution with significant benefit.

The PP Control & Automation solution

Engineers from both companies came up with a new way of assembly that involved developing a more standard enclosure system, which would allow the panel to be easily slid into the machine.

Once a successful enclosure system design was created, the cable harnessing and the interconnectivity around the machines could be considered. It became apparent early in the process that a modular approach would be a lot more cost and time effective.

PP were then assigned the task of designing a process that would see the modules fully assembled at its world-class facility.

Cable harnesses were designed to ensure that they were jigged to the optimum lengths and therefore could be plugged straight into the mating halves around the machine, whether distributing power or signals.

ABG could make the switch from hard wired sensors to M8 and M12 connectivity, allowed for swift assembly and test. Using distributed I/O technology vastly reduced wiring time and paved the way for a complete ‘plug & play’ assembly process around the machine.

As a spin-off project, PP and ABG collaborated on a Power Distribution Unit that mounts at the front of the machine and distributes the power to each of the modules.

  • Modular control system design
  • ‘Plug & play’ style connectivity
  • Distributed I/O
  • Standardised power distribution

The real business benefits

Thanks to our commitment to outsourcing, we are now more efficient and have cut production and sales lead times significantly. Importantly, PP has also given us the additional capacity that allows us to go after new business safe in the knowledge we can quickly ramp up production to cope with it.

Phil Robson, Operations Manager
A B Graphic International Ltd

  • 60% improvement in electrical fit-out time
  • Eliminated 700 days of production each year to be re-allocated to other areas
  • Production capacity increased by over 50%
  • ABG now offer custom module configurations to customer specific machine requirements

Control & Automation | Contract Manufacturing | Strategic Outsourcing

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