Industrial Solutions

Overview

GijimaAst Industrial Solutions (IS) a division within the GijimaAst Group has a proven track record in supporting the manufacturing process from raw material input, processing, logistics, financials and human resources, through to distribution.

Our solutions in both Automation and Manufacturing Execution Systems (MES) are based on the successful combination of technological and business innovation at every stage of the value chain.

Our expertise is world class and international best practice based. Seen in the context of our manufacturing process knowledge, extensive ICT services and e-enabling capabilities, we offer our partner the potential to become an enterprise that is dynamically optimised to the rapidly changing manufacturing environment.

Consulting

Manufacturers need to step back and take a holistic view of their operations. An event on the shop floor has many business implications that the manufacturer has to evaluate and anticipate. These events may have far reaching implications that affect other systems in unexpected ways; to understand these implications requires a good holistic and sometimes an in-depth knowledge of the business processes and systems involved. Often a plant operator will try to correct these events and invariably cause other events further up in the processes and systems.

Think through the manufacturing process. Identify the six or seven events that cause 80 to 90 percent of the shop-floor problems; don't view them in isolation. If manufacturers understand the problem-causing events and their interactions, they can put into place the business processes that can resolve these events quickly and profitably.

Some of our Consulting Services are:

• Integrated Manufacturing Strategy;
• Road Map & Cost Benefit Analysis;
• Vendor selection;
• Design, Tender and project reviews;
• Business Process Design with KPI Analysis;
• Group Technology & Standards facilitation;
• New Product or Service Offerings Evaluation; and
• Risk Management Strategy.

Engineering Services

We provide a mixture of consulting engineering, project management, and construction services to provide our clients with complete turnkey control system solutions. Cardinal to our success is the fact that we regard Automation as a solution and not a technology.

Services that we offer include:

• Control System Architecture Design;
• Hardware & Architecture Configuration;
• Design and implementation of Human Machine interfaces using various technologies;
• Interfacing to Intelligent sensors and existing control systems; and
• Together with our MES capabilities we design “Shop Floor to Top Floor integrated solutions.

Electrical Design and Installation

When we design and manufacture drive and motor control systems, as part of a total automation project, you are assured of a system designed by recognized professionals, incorporating the optimal choices among power, logic and process control systems into one system.

This includes:

• Preparation of Detailed BOM (Bill of Material);
• Cable rack & route design for Electrical and Instrumentation Cables;
• Control System Design;
• Motor Control Centre Design;
• HT Sub-Station & LT Power Distribution Design;
• Detailed specifications of instruments and P&ID diagrams;

PLC & DCS Engineering

A significant portion of our engineering staff was successful plant engineers and all are familiar with the workings of industrial manufacturing facilities.

Our PLC & DCS Engineering Services include:

• PLC & DCS Engineering according to ISO Standards;
• Fully S88 compliant & documented engineered solutions;
• Device orientated approach with strong methodologies;
• Extensive proven libraries;
• Advanced Automation networking methodologies;
• Risk avers software development; and
• Specializing on online changeovers & high risk projects.

Installation, Commissioning & Start-up

We have field service technicians who specialize in system installations. They understand the objectives, the technologies and the constraints. They work together with our system engineers to ensure each client's project is installed correctly, on time, and within budget.

Manufacturing Execution System Design and Implementation

Successful MES integration starts with a good understanding of how to acquire, store and validate vital manufacturing data in such a way that it can be converted into useful information, made available in a transparent and comprehensible way to anyone who needs it i.e.: planning, production management, administration, logistics, engineering, quality control, human resource management, suppliers, customers etc. The Solutions delivered are based on international standards such as S95.

Our professional Design and Implementation Services are based on a phased approach. Each phase is clearly defined, estimated and can even be contracted separately, with specific deliverables at each completion. The completion of each phase reduces the risk for subsequent phases by increasing the level of information about the required system. Our experience has shown that this approach produces better systems at lower costs and lessens the risk for both the customer and the implementer.

Planning

During this phase the Detail Project Plan is finalised, the Project Office is established, any uncertainties regarding the Conceptual System Design are clarified and the project Quality Assurance plan is put in place. Clarification of ambiguous requirements defined within the contractual documentation is completed and abbreviated requirements will be expanded on by means of Request for Information (RFI) forms.

Implementation

User Requirement Specification
GijimaAst Industrial Solutions prepares descriptions of the system functions and the user interfaces based on the functionality required by the client. This document forms the baseline for the Functional Analysis Specification and it requires written approval by the Client, prior to the start of the next phase.

Functional Analysis Specification
The Functional Analysis Specification (FAS) includes further detail of the solution. IS prepares detailed system functions and user interfaces. This document forms the baseline for the next phase and therefore requires the written approval by the Client, prior to the start of the next phase.

Tailoring and Integration
During this phase, the GijimaAst Industrial Solutions project team will configure and develop the system according to the approved FAS. The data dictionary, database design, database layout, program modules and module interfaces are laid out.

Software coding/configuration begins and continues until all software modules are developed and unit-tested. After unit-tests have been completed, all the components of the system are integrated, and integration testing is performed. Upon successful completion of this phase, the system is ready to be delivered to the site.

Implementation
During this phase the solution is delivered to site, installed into the actual plant environment, connected to the relevant plant equipment and networks, and started up. Training performed during this phase and would typically include applicable technical training on the software packages used in the development of the application as well as application specific training on the solution components as documented in the various user manuals. At the end of this phase, the user has full, beneficial use of the proposed solution. The aim of the training phase is firstly to enable users to successfully use the system and secondly to enable the client to be self sustainable.

Regional Support and Maintenance
Apart from our Project Implementation capability GijimaAst Industrial Solutions are positioned to deliver 24 hour on site support on critical systems within the Plant/Production environment.

We have offices in Middelburg, Richards Bay, Newcastle and Vanderbijlpark where we offer services that cover the full system lifecycle, which includes system enhancements, maintenance, fault finding and optimization.

Project Management
Strong Project Management ensures that schedule, cost and quality objectives are met. GijimaAst Industrial Solutions has proven methodologies for executing Industrial Solutions projects.

GijimaAst Industrial Solutions works closely with the client to clearly define the project scope, schedule, cost and execution details. GijimaAst Industrial Solutions also manages the vendors selected to provide hardware and software.

For each project, GijimaAst Industrial Solutions carefully selects a project team with the appropriate skill set necessary to successfully execute the project. Project team personnel are knowledgeable regarding the industry processes and the technologies required. This ensures practical, cost effective and timely solutions.

Technology Vendors
GijimaAst Industrial Solutions will maintain its stand of not being product specific, partnering with a very few carefully selected companies which enables the provision of product-neutral business solutions.

Current Technology partnerships include:

• Siemens (Automation and MES);
• Aspentech (MES);
• CSense and SysCad (Process Optimisation and Control); and
• Wonderware (SCADA and MES).