Anonymous Rare Earth and Metal Products Manufacturer

A leading global manufacturer of rare earth and metal products acquired a California facility for conversion to a state-of-the-art mining operation spanning 14 buildings designed by eight separate engineering firms. The challenge was to engineer and implement a homogenous sitewide process control system within 18 months across all buildings.

Thermo Systems LLC, a Rockwell Automation Solution Partner, created an automation master plan and implemented a scalable process control solution. The system provided production intelligence by collecting and reporting data from disparate sources, integrating skid, plant-floor, and electrical systems with analysis and reporting portals.

The facility achieved improved diagnostics and process efficiencies through increased access to real-time data. The integrated end-to-end solution significantly reduced staff training and maintenance costs. Standardized control across 14 buildings was deployed within the 18-month timeline.

• A standardized automation master plan is essential when multiple engineering firms work on a single facility • Centralizing process intelligence across disparate buildings reduces long-term training and maintenance costs • Solution partners play a critical role in delivering complex, multi-site automation programs on schedule