Case Study

Legacy Control Systems Modernization

Tire Manufacturer ABC
3

The Problem

Tire Manufacturer ABC was operating on an aging control platform that resulted in frequent downtime, limited data visibility, and increasing maintenance costs. System failures were becoming more frequent, impacting production schedules and overall efficiency.

The Challenge

The goal was to modernize the control system without disrupting ongoing production. This required integrating new PLCs and HMIs with legacy equipment while maintaining uptime and ensuring a seamless transition for operators.

Project Approach

Card-Monroe Automation executed a phased modernization strategy designed to minimize risk while maximizing system performance and scalability.

  1. System Audit. Full evaluation of existing PLCs, HMIs, and network architecture.
  2. Control System Redesign. Developed updated architecture using modern PLC platforms.
  3. Implementation. Installed and integrated new hardware with minimal downtime.
  4. Commissioning. Validated system performance and trained operators.

Unique Challenges

  • Integration with legacy tufting equipment
  • Tight production schedule constraints
  • Custom communication protocols

What We Did Well

  • Seamless integration with minimal downtime
  • Clear communication throughout the project lifecycle
  • Flexible engineering approach to solve unexpected challenges

Key Metrics

Schedule
10 Weeks
Engineering Hours
420

Project Summary

The upgraded system delivered improved reliability, enhanced data visibility, and increased production efficiency. Tire Manufacturer ABC now operates on a scalable platform ready for future expansion.

Message from the PM

This project required careful coordination between legacy system constraints and modern control architecture. Through a phased approach and close collaboration with Tire Manufacturer ABC, we delivered a seamless transition that improved system performance without compromising uptime.

Kyle Swing
Project Manager

CMA delivered exactly what we needed on time and with minimal disruption.

Customer Feedback
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