Ethicon, a division of Fortune 500 pharmaceutical company Johnson & Johnson, is a global leader in surgical technology, specializing in the production of sutures, surgical staplers, energy devices, and other advanced medical tools used in minimally invasive and open surgeries. At their New Jersey facility, Ethicon was relying on a 1980s Macbee wire annealing line that had outdated components leading to inefficiencies and rising maintenance costs. Recognizing the need for a reliable upgrade, Ethicon turned to EDC.
Problem
The wire annealing line was necessary for Ethicon’s production process to achieve the necessary ductility for further processing. The original system, which consisted of 15 sections with individual capstan and takeup drives, had become problematic due to the obsolescence of its components. Stretching across the length of the manufacturing area, the system was controlled by outdated DC drives. The risk of prolonged downtime due to the lack of available replacement parts was a significant concern, as was the need for better speed regulation and operator control.
“The 15 takeup DC drives were in individual 30 by 30 inch enclosures spread out along the entire manufacturing floor,” said Chuck Dillard, Vice President at EDC. “Ethicon needed a solution that would not only update the technology but also reclaim some of the limited floor space and improve the overall system efficiency.”
EDC established a reputation for reliability by successfully completing multiple machine upgrades for the company over several decades. When it came time to upgrade the wire annealing line, Ethicon turned to EDC, looking to address the challenges of part availability and enhance the system’s performance.
Solution
EDC recommended a comprehensive retrofit, converting the outdated DC motors to modern AC motors and replacing the legacy control system with a more compact and efficient solution. The project involved installing Siemens S120 drives and a Siemens S7-1500 PLC, coupled with remote I/O to streamline the control process. “There was limited space at each machine, so we utilized point I/O to use the smallest footprint for the remote I/O,” noted Dillard.
To minimize the footprint of the control system, EDC designed two compact enclosures, each containing Siemens double motor modules that each managed half of the line’s 16 sections. This consolidation drastically reduced the required floor space, improving the layout and accessibility of the manufacturing floor.
Key Upgrades
| Feature | Description |
|---|---|
| Conversion to AC Motors | EDC replaced the 30 DC motors with Marathon vector AC Black Max motors, enhancing reliability and performance with encoder feedback for precise speed regulation. |
| Compact Enclosures | The new enclosures, each measuring 60 inches wide by 36 inches high, housed Siemens double motor modules, reducing the system’s physical size. |
| Enhanced Operator Interface | A new operator station with a large display screen was installed, providing real-time data on each section of the machine. This allowed operators to monitor performance and make adjustments more efficiently. |
| Common DC Bus | The retrofit included a common DC bus for the drives, resulting in significant energy savings and improved operational efficiency. |
| Remote I/O Integration | Utilizing Siemens remote I/O, EDC ensured reliable communication between the drives and the PLC, while minimizing the interwiring. |
| Safety and Compliance | EDC adhered to Ethicon’s additional safety standards, conducting a Job Safety Analysis (JSA) and obtaining the necessary permits for installation. |
| Validation | Since Ethicon is a medical device company, it is regulated by the FDA. EDC was very much aware of this requirement and supported Ethicon with executing the detailed test scripts. |
Results
The retrofit resulted in a more efficient, reliable, and user-friendly wire annealing line, with significant improvements. The enhanced control provided by the Siemens S7-1500 PLC, along with the encoder feedback from the new Marathon AC motors, ensured precise speed regulation. Advanced communications between the drives and PLC, along with a common DC bus, delivered better process visualization and substantial energy savings, all while allowing for remote troubleshooting.
EDC engineers designed two compact enclosures, each 60 inches wide by 36 inches high, to house the Siemens double motor modules. This consolidation not only reduced the system’s physical footprint but also enhanced the overall accessibility of the manufacturing floor. The system’s new design also freed up valuable floor space, and the use of modern, readily available components eliminated the risk of extended downtime due to part obsolescence. The project was completed with minimal disruption to Ethicon’s operations, and the system was fully functional after only 5 days of downtime.
EDC conducted preliminary work before the upgrade to ensure a smooth transition. During the shutdown, a team of mechanical and electrical engineers carried out a full functional test to validate the system’s readiness. This included a factory acceptance test at EDC’s facility, where Ethicon was able to review and verify the system’s functionality.
“Our experience with the system has been exceptional,” said Raj Makhijani, Staff Process Engineer at the Ethicon wire mill. “It has significantly streamlined our operations, improved efficiency, and exceeded our expectations. The team’s dedication and expertise were evident throughout the entire process, and we couldn’t be more pleased with the results.”
