There are several ways in which motor control centres can be made more cost-effective.

• Bit-level networks to replace traditional hardwiring
• MCCs in this category are characterized by simplicity. They will almost always deliver the lowest installed cost. They allow localisation of failures to improve maintenance and usually provide some additional functionality not economically feasible with hardwired systems.
• Installation and commissioning time is significantly improved over traditional MCCs. They do not require extensive system configuration or parameter management and can be maintained by most electricians. Concurrent engineering also is greatly facilitated.
• Bridges are available to most bit-level or byte-level networks and configuration is straightforward (an entire MCC is typically represented as one node). Computational resource and network bandwidth requirements are low.
• These systems are easily retrofitted to existing installations and do not require “intelligent devices” to provide benefits.
• Reduced footprint is possible which helps if space is an issue.

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In an increasingly competitive world differentiating is harder than ever. One way this is possible is through improving the customer experience at every stage of their interaction with your business.

Saftronics Ltd, a leading UK motor control centre manufacturer, recognised this and embarked on a significant Customer Journey Mapping exercise delivered by Progress Marketing Ltd with the help of Manufacturing Growth Programme funding.

A customer journey map is a visual representation of every experience your customers have with you. It helps to tell the story of a customer’s experience with your brand from original engagement and into hopefully a long-term relationship.

Progress Marketing worked alongside the senior management team at Saftronics to scope the specifics of the project. They conducted interviews across the business from sales and marketing, to projects management, engineering, manufacturing to installation to assess current process and work flow. Processes were mapped and detailed noting timeframe, customer pain point and goals and opportunities.

Customer journey mapping helps businesses step into their customer’s shoes and see their business from the customer’s perspective. It helps businesses gain insights into common customer pain points, how they can improve the customer experience, and define what customers, and prospective customers, need in order to complete a purchase. This type of project is essential to help you better understand the needs of your customers. These change over time and expectations have been raised as a result of technology improvements but often companies are still doing what they have always done for years without adapting to these new demands.

The project has had a positive impact for Saftronics enabling them to improve the onboarding process for customers, retain more customers to deliver repeat orders and focus on building brand advocates to lead to more referrals.

The Manufacturing Growth Programme (MGP) were delighted to provide grant funding support towards the cost of the consultancy project between Saftronics and Progress Marketing. The fund is used to help facilitate business improvement projects between eligible manufacturing clients and external business growth experts / consultants. The MGP is delighted with the outputs of this project following the creation of five new full time positions within the organisation, coupled with a plan for long term profitable growth.  

For more information on the Manufacturing Growth Programme, visit; www.manufacturinggrowthprogramme.co.uk

Use of open networks, distributed I/Os, and electronic components is one way of defining an MCC as intelligent.

Typically, intelligent systems have three things in common:

• Control is achieved through a microprocessor-based system
• Network technology is used to replace hardwiring
• Some degree of enhanced diagnostic or protective functionality is included.

While many associate these technologies with intelligence, another definition has nothing to do with the technology involved. In today’s competitive business environment, perhaps the definition of an intelligent MCC should be as simple as a unit that provides equivalent or greater functionality more economically. In other words, an intelligent MCC is simply an MCC that maximises the value of the components in a given application.

But how does one determine maximum value? Is it based on the cost of the equipment? That definition doesn’t take into account the total cost of the unit. In other words, the cost to design, specify, purchase, install, commission, operate, maintain, and upgrade an MCC are all calculated into the total cost of ownership.

Each individual in the chain is likely to define intelligence related to his or her perception of value. For example, consultants who design and specify equipment are interested in the reliability and performance of the components. A contractor may be primarily concerned with installed cost. A facility manager is likely to be worried about ease of operation and maintenance costs. And operations personnel are focused on the functionality and durability of the entire system. In other words, regardless of a person’s function, a truly intelligent MCC will optimize the value of the equipment specific to that function.

Why use a Motor Control Centre?

The role of a basic Motor Control Centre (MCC)  is to provide a compact, modular grouping for motor control and electrical distribution components. Think of an MCC as a filing cabinet, with drawers full of combination starters, lighting contactors, and other electrical distribution and control products. Historically, MCC units were electromechanical, with basic functions that included a power switching device, short-circuit and overload protection, local and remote actuation, and controller state indication.

Benefits of an MCC

• MCCs provide a single source for coordination of components. Electrical distribution and motor control equipment can be purchased as a pre-assembled, pre-tested system—usually at a less expensive installed cost when compared to separately mounted controls.
• MCCs require significantly less line-side power wiring than separate controls, which makes them easier to install.
• MCCs come in space-efficient packaging, with excellent configuration flexibility. They also centralise maintenance.
• MCCs offer excellent fault containment and electrical component isolation.

MCCs are used in applications where there are multiple, remotely controlled loads linked to a central control point. In industrial plant applications, the central control point is usually an environmental control system, with HVAC, pump, and fan loads. Industrial process applications include many load types, such as conveyors, pumps, fans, and mixers. These loads often require coordinated control and can be the source of important process or machine diagnostic information. Distributed control systems (DCSs) or PLCs normally are used to provide this control and data acquisition functionality.

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