A tier-one electroplating plant battled transporter traffic jams that stretched cycle times and drove expensive rework. By deploying an end-to-end industrial automation package from Symbiotic Automation, the site coordinated every hoist in real time and boosted daily output by a quarter.

Challenges Faced

• Uncoordinated transporters collided at tanks, causing dwell-time variance and uneven thickness.
• Paper batch logs obscured yield trends and slowed root-cause analysis for customer claims.
• Conventional buzzers were lost in shop-floor noise, so alarms went unnoticed until scrap accumulated.

Implementation

A dual-CPU PLC backbone now orchestrates simultaneous transporter motion against dynamic bath availability. Each rack’s immersion, current, and dwell profile streams to a SQL data mart. Clear, human-voice annunciators broadcast deviations, keeping operators alert without pausing production.

Key Implementations

• Hot-standby PLC architecture ensuring zero downtime and safe collision-avoidance logic
• Recipe-driven scheduler matching rack, chemistry, and dwell parameters automatically
• Batchwise reports linking process curves to genealogy for fast audits
• Central data-management system archiving cycles, thickness, voltage, and temperature
• High-fidelity audio annunciation with multilingual voice prompts for alarms and safety

Outcomes & Benefits

• 25 % faster cycle time—monthly capacity up without new hardware
• 100 % electronic traceability—batch records export in seconds, cutting customer response from days to minutes
• 40 % scrap reduction after actionable voice alerts replaced inaudible buzzers

Future Scope

Building on the new data backbone, the plant can link inline thickness gauges and chemical analyzers to automatically adjust dwell times and dosing, further stabilizing quality and reducing operator intervention.