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An Introduction To The KEY Group Organisation
Corporate Mission Statement “KEY Group Solutions Limited is a privately owned UK Company, offering full Turnkey Project Solutions within the Automotive, Aerospace and leading Manufacturing and Process Industries. ” “Working Closely with the customer to maximise their requirement, the latest ‘State of the Art’ Technology, enables KEY Group to develop the most appropriate and cost effective solutions for our international clients. ” “Offering the ‘Best Available Technology’ and developing with the customer the smooth transition of Technology Transfer emphasises our commitment to Continued customer support. ” Kevin Dodson – Managing Director
Our Background Privately Owned Group Of Companies Established In 1999 Turnkey Supplier To Automotive & Process Finishing Industry Central UK Location With Midlands Based Offices Efficient Seamless Infrastructure Suppliers Of ‘Cutting Edge Technology’ KEY Supports A Fully Integrated Documented Quality System
Corporate Structure KEY Technical Solutions KEY Property & Developments KEY International Projects UK Turnkey Projects Residential & Commercial Property Portfolio Overseas Projects Control System Solutions Property Asset Management 25, 000 UPA Paint Shop Successfully Completed 102 Projects Building / Property Development 10, 000 UPA Engine Facility
KEY Head Office Ideal ‘Back Bone’ Of The KEY Organisation 10, 000 sq. ft of Prestigious Offices In Central UK Management and Engineering Personnel Fully Integrated IT Networked Systems Customer Training Facilities
1 st Tier Supplier Status
Core Products ‘A graphical user workstation designed for the complete control of an Automated Paint Application process’ - Unlimited Style & Colour Quantities - Open Architecture Database - Extensive Production & Management Reporting - Comprehensive Alarm Management
Core Products (Cont. ) ‘Retractable Booth Flooring’ Minimum Impact On Air Flow – Reduced Cleaning Costs
Proven Experience You Can Trust “KEY possess a wealth of project management experience and as a result are positioned to undertake contracts of any scale or duration. ” “KEY are able to provide the role of ‘Principal Contractor’ as defined within the CDM regulations. ” “KEY offer Process Engineering support and design services that ensure our customer utilise ‘Best In Class’ processes at every stage. ” “From process optimisation to complete facility layout and design our engineers can help your business. ”
KEY Core Capabilities Project Management and Principal Contractor Industrial Process Plant Supplier Mechanical and Electrical Design Computer Aided Design (CAD) PLC Control Software Design Management & Supervisory Computer Systems Complete Plant Wide Integrated Solutions Services & Facilities Management Feasibility Studies Business Requirement Documents Functional Design Specifications (FDS) Procurement International Freight Forwarding Mechanical & Electrical Installation Commissioning & Robot Programming Engineer & Operator Training Site Support Services
KEY Fields Of Expertise Total Factory Integrated Solutions for: Press Shop Body-In-White Paint Shop Trim & Final Power Train
KEY Fields Of Expertise (Cont. ) Adhesive / Sealant Booths, Robotic Welding Cells, Highlighting Booths, Panel & Body Wash Systems, Forming Machines, Assembly & Finishing Solutions Pre-Treatment, Electro-Coat Painting, Spray Booths & Enclosures, Infra Red & Conventional Ovens, Air Replacement Units, Paint Mix Systems, Paint Application Equipment, Water Treatment Plants, Thermal Oxidisation
KEY Fields Of Expertise (Cont. ) Robotic Glazing Cells, DC Tooling, Fluid Farms & Dispensing Systems, Water / Strom Test, Line Side Logistic Systems CNC Machining Centres, Automated Assembly Machines, Leak Test, Final / Sub Assembly Lines, Hot & Cold Test, Robotic Component Handling
An Overview Of KEY Expertise & Project Experience
“Control System Solutions”
Control System Solutions & Electrical Installation A corner stone of the KEY organisation is the design, manufacture and installation of ‘Turnkey’ Control System Solutions. Whether it’s a large ‘Turnkey’ Control System project with a complex suite of panels, or modifications to an existing system our experienced team are able to provide a solution. KEY has a dedicated ‘In-House’ design team working with the latest software packages to deliver Innovative ‘State of the Art’ System Solutions. All site installations are managed and undertaken by our specialist team in full accordance with our own quality procedures and CDM regulations. KEY are also able to offer a range of bench test and modular build services as well as final commissioning, PLC Software Design and Robot Programming.
Control System Solutions & Electrical Installation (Cont. ) Full ‘Turnkey’ Control System Project & Contract Management Innovative ‘State of the Art’ System Solutions Complete System Design and Electrical Drawings Comprehensive Range of Standard Drawing Packages All Systems Fully Compliant to Latest International Standards Extensive Experience In Working Within ‘EX’ Rated Environments No Commercial Ties To Any Equipment or PLC Suppliers Electrical Equipment Procurement and Delivery Dedicated In-House Site Management & Installation Team In Excess Of 30 Years Experience In Large Installations Established Safe Working Practices In Line With CDM Low Voltage (LV) and High Voltage (HV) Systems Modular Build and Bench Testing Of Systems System and Software Commissioning Services
Durr (APT) – Robotic Paint Application Equipment Durr (APT) selected KEY to work as their partner in the first UK installations of their highly successful 7 axis Paint Application Robots. Resulting in a number of complete ‘Turnkey’ electrical Control System Projects. The role of KEY was the ‘Turnkey’ supply of the electrical Control System and associated panel suite for the individual robots. The scope of supply Included; design, manufacture and site installation. The systems were each modular built prior to final installation, with KEY providing a full team of both electrical and commissioning engineers during this critical project phase. The final systems when installed at the customers sites were fully integrated into existing Plant Wide PLC, Network and SCADA systems to provide the ultimate solution.
Durr (APT) – Robotic Paint Application Equipment (Cont. ) Full ‘Turnkey’ Robotic Electrical Control System Projects Electrical and Software Contract Management Complete Control System Design and E-Plan Drawings Electrical Component and Equipment Procurement Manufacture of Control Panel Suites & Bench Test Modular Build of System at Durr Factory In Germany Electrical and Software Support of Modular Build Phase Electrical Field Installation at Clients Facility Utilising In-House Team Site Management In Accordance With Safe Working Practices & CDM Equipment Installed Within an ‘EX’ Rated Environment Final Systems Fully Commissioned and Documented All Projects Completed On Time and Within Budget
Jaguar – Castle Bromwich – SVO Control System The Special Vehicle Order (SVO) Control System installed within the Paint Shop at Jaguar Cars Castle Bromwich caters for the painting of ‘one’ off vehicles to satisfy specific colour requests of the customer. The paint application equipment was based on the latest ‘Push-Out’ colour change technology in order to keep paint usage to an absolute minimum. Implementation of this required KEY to redesign the electrical Control System to cater for additional Air, Paint and Solvent Valves. The existing Modicon 984 PLC equipment was replaced with a new Quantum Series solution fitted with a Co-Processor to mange the expanded Paint Application and Colour Change data. The existing remote Input/Output (I/O) racks were added to encompassing the control of the additional valves. The I/O racks were accessed by the main PLC Processor via new Remote I/O Scanner cards.
Jaguar – Castle Bromwich – SVO Control System (Cont. ) Complete ‘Turnkey’ SVO Paint Application Control System Conversion of 9 Bell Basecoat ESTA and 6 Gun Reciprocator Zones Modicon 984 PLC’s Replaced With New Quantum Series Equipment Expanded Paint Data Managed Via Introduction of Co-Processors Additional Remote I/O Racks Handling New Paint, Air and Solvent Valves Replacement Electrical Drawings In E-Plan CAD Format PLC Software Expanded and Converted From 984 to Quantum Logic New Interface to Communicate With Durr ECO Paint SCADA System Design of Software Interface Between PLC and BOSCH Motion Controller Full Electrical Installation and Modification of Existing Panel Suites Final System Commissioning, Operator Training and Production Support
“SCADA & Network Systems”
Factory Integrated SCADA and Network Systems KEY has developed a reputation for the design and implementation of ‘Bespoke’ Graphical Operator Interfaces and System Controls. What ever your business demands whether a Plant Wide Integrated SCADA system or a local Human Machine Interface (HMI) our team of software designers will deliver a user friendly solution built to suit your needs. Comprehensive Management and Production reporting systems can be realised with the use of standard software packages such as Microsoft SQL or Access. KEY are also pleased to offer our clients an extensive range of network solutions designed to collate the data required to generate meaningful operator screens.
Factory Integrated SCADA and Network Systems (Cont. ) Designed to Suit Customers Specific Needs Monitor and Control Plant Wide Machines & Facilities Production and Management Reporting Systems Standard Software Applications and Tools, Including GE Cimplicity Wonderware RS View / Panel Builder Factory Integrated Network Solutions Ethernet RS 485 / 232 Dedicated PLC I/O Networks Wi Fi Communication Systems All Systems Fully Developed & Commissioned In-House Comprehensive Documentation & Customer Training Microsoft – SQL & Access Databases
BMW – Vehicle Management System (VMS) The Vehicle Management System (VMS) is utilised within the Paint Shop at BMW Plant Oxford to both graphically ‘Map’ the location of all bodies currently travelling through the facility, and also manage Colour, Style, Storage Locations and Production Flow. VMS interfaces directly with existing BMW logistic systems in Germany to determine customer order derivatives. The collated data is tracked with the body as it travels through the facility which is automatically transferred to the Paint Application and Process equipment as required. The VMS system provides a vast range of both automatic and manual routing controls, which include full control of Conveyor Strip Out and Storage areas to cater for optimised production flow. The final solution was based on Allen Bradley Control Logix PLC systems and GE Cimplicity SCADA Graphic packages.
BMW – Vehicle Management System (VMS) (Cont. ) Special Purpose SCADA & PLC Based Vehicle Management System Fully Designed and Implemented In Partnership With The Customer Comprehensive Range of ‘User Friendly’ Graphics and Features Interfaces Directly With BMW Systems To Manage Vehicle Derivatives Logistic and Production Management Tools To Control Production Flow ‘State of the Art’ Allen Bradley Control Logix PLC Solution ‘Hot Standby’ PLC Eliminates Downtime In This Mission Critical Systems Communicates With Paint Application Equipment To Manage Body Colour Networked Baumer Bar Code Readers Utilising The RS 485 Protocol Microsoft SQL Production and Management Report System Configurable Microsoft Access Based Production Reporting System Dynamic Production Statistic Summary – Real Time Vs Target
Vauxhall Motors – SCADA and PLC Upgrade Vauxhall Motors awarded KEY the prestigious contract to upgrade the existing SCADA and PLC systems utilised within the Paint Shop facility at their Ellesmere Port Plant. The basis of the project was to upgrade the existing GE Fanuc Cimplicity SCADA package to the latest revision. Whilst performing the upgrade all existing screens were reviewed to improve graphical representation and functionality. In addition the existing Series 6 PLC equipment was upgraded and replaced with new Processors, Main Racks and Ethernet Modules from the GE 90/70 Range. The Genius I/O networks were reconfigured to connect to the new Processors and the whole solution was integrated into the Plant Wide Ethernet network.
Vauxhall Motors – SCADA and PLC Upgrade (Cont. ) Upgrade of GE Cimplicity SCADA Package To Latest Revision All New Screens To Provide Improved Appearance & Functionality Integration of Final SCADA Solution Into Plant Wide Graphics System Automated Plant Start & Stop Sequences From Within SCADA Installed Xycom Flat Panel Operator Touch Screen Terminals Replace Existing PLC’s With Equipment From GE Fanuc 90/70 Series Expanded Plant Ethernet To Accommodate New PLC Systems System Modifications Undertaken In Non Productive Weekend Periods The Process Equipment Upgraded Included : Paint Mix Air Replacement Plants Paint Application Booths Primer and Colour Ovens
Electro Mechanical Turnkey Projects KEY Group offer full Electro Mechanical ‘Turnkey’ Solutions to The Automotive, Aerospace and leading Manufacturing and Process Industries. The KEY Group are renown for solutions that provide ‘Cutting Edge’ and Best Available Technologies. Fully supporting the principle of complete Technology Transfer. KEY Group have a reputation for completing full ‘Turnkey’ Projects, within budget and on time. It is this level of experience in design, installation and contract management that provides the confidence to undertake projects of any scale. Our customers can rest assured that any project managed by KEY will be completed without risk.
Electro Mechanical Turnkey Projects (Cont. ) Full ‘Turnkey’ Industrial Process Plant Supplier Principal Contractor & Planning Supervisor as Defined In CDM Complete Electrical and Mechanical Facility Design Civil Engineering and Design Capabilities Computer Aided Design (CAD) and E-Plan Services Programmable Logic Controllers (PLC) Software Design Plant Wide Integrated Network Solutions Functional Design Specifications (FDS) Feasibility Studies and Proposals Business Requirement Documents Global Procurement Processes Electrical and Mechanical Installation Teams Commissioning and Robot Programming Engineer and Operator Training
Land Rover – High Velocity Blowers Land Rover – Solihull needed to increase their already high quality Standards with the introduction of ‘High Velocity Blowers’ into each of their five existing Paint Application Booths. The Blowers and associated tunnels were designed to be directly integrated into existing Paint Booths, with conveyors systems being modified to direct the bodies through the Blower enclosures. When completed Blowers remove all loose ‘debris’ from the bodies prior to final Paint Application achieving the required increase in quality standards. KEY Group undertook the roles of both ‘Principal Contractor’ and ‘Planning Supervisor’ in accordance with current CDM Regulations.
Land Rover – High Velocity Blowers (Cont. ) Principal Contractor and Planning Supervisor Roles Complete ‘Turnkey’ Project Solution Five Complete ‘High Velocity Blower’ Systems Seamless Integration Into Existing Paint Application Booths Automatic Body Recognition System For Contour Profiling Complete Electrical and PLC Control System ‘Bespoke’ SCADA Package For Input of Parameters & Contour Mechanical and Electrical Installation Utilising In-House Team Complete Mechanical and Electrical Conveyor Modifications System Commissioning and Contour Programming Works Undertaken and Completed Within Shutdown Periods Production Launch Support and Operator Training
MG Rover Powertrain – ‘L’ Series Diesel Line MG Rover – Powertrain contracted KEY Group to re-locate and re-engineer the ‘L’ Series Diesel Engine Line. Undertaking the role of Principal Contract the existing facility was de-commissioned, stripped out, transported from Land Rover Plant and installed within a new two storey Powertrain facility at MG Rover Longbridge. KEY re-engineered the complete assembly process resulting in a configuration from 170 metres with 60 stations to 120 metres and 45 stations and included off-line test facilities. The complete program of works was concluded in just 9 weeks from removal to first production units at the new location.
MG Rover Powertrain – ‘L’ Series Diesel Line (Cont. ) Full ‘Turnkey’ Project and Principal Contractor as Defined In CDM Disassemble and Transportation From Land Rover Solihull Original Process Length of 170 Metres / 60 Stations Re-engineering for New Process Length of 120 Metres / 45 Stations Complete New Electrical Field Installation Re-Calibration of DC and Pneumatic Tooling Commissioning, Operator and Engineer Training 9 Weeks Total Program of Works Production Launch and Quality Support
Existing Facility Up-Grades and Refurbishment The modern day business model demands that organisations operate with maximum productivity and efficiency, in order to be able to compete in the Global Market. Recognising this fact KEY are able to offer our clients a range of services aimed at achieving these shared goals. Frequently the business needs of our clients dictate that the life of an existing facility or flexibility must be increased, with this in mind KEY are pleased to offer tailored Refurbishment or Upgrade Packages. KEY appreciates increases in energy costs often place strains on a clients operational budget. KEY has developed a range of site studies and engineering services focused on the reduction of energy usage.
Existing Facility Up-Grades and Refurbishment (Cont. ) ‘Turnkey’ Facility Refurbishment and Upgrades Refurbishment of Existing Equipment New or Additional Equipment and Facilities Electrical or Mechanical Projects Maintenance Engineering and Support Services Productivity and Flexibility Improvements Business Requirement Documents Facility Feasibility Studies and Reports Energy Reduction Surveys and Proposals Energy Efficient Motors Inverter Motor Control Replacement Pumps & Fans Capacity to Manage Projects of Any Scale
Perkins Engines – Vista 3 Cylinder Head Line Perkins Engines (Peterborough) needed to increase the production volume of their existing Vista 3 Cylinder Head Manufacturing facility from 14 to 16 Units Per Hour. In order to achieve the desired increase in volume it was necessary to introduce two new CNC Machining Centres with automated Robotic loading. In addition the process / assembly equipment layout was revised and new Inter Machine Component Handling System installed. The fully automatic Inter Machine Component Handling System was fitted with a new Telemecanique based Electrical Control System and associated PLC software. New Over Conveyor Coolers were installed on the exit of the Chemical Wash machine to allow for manual handling of the machined component through the quality inspection station.
Perkins Engines – Vista 3 Cylinder Head Line (Cont. ) Increased Production Capacity From 14 to 16 Units Per Hour Two Additional New Agile CNC Machining Centres Revised Layout of Process and Assembly Equipment Fully Automated Inter Machine Component Handling System Powered Roller Conveyors Component Lift and Orientation Stations New Telemecanique Based PLC Control System and Software Replacement Electrical Field Installation and Devices New Scissor Lift Pallet Load Into Machining Cell Installed Manual Handling Assistors at Non Automated Stations New Over Conveyor Component Cooling Facility All Works Completed Within a 2 -Week Shut Down Period
BMW – Inverter & Pump Upgrade The objective of the project within the Paint Shop at BMW Plant Oxford was to analyse the annual energy usage and investigate methods of reducing operational costs without impact to either volume or quality. In order to develop recommendations a detailed survey was conducted to encompass all pumps and fans within the facility. The outcome was a clear understanding of both existing operational conditions and equipment efficiency. It was identified that the most cost effective method of achieving the required energy savings would be the installation of Inverter Motor Controls to a number of existing Pre-Treatment Pumps and main Spray Booth Exhaust Fans. It was also discovered that the existing pumps within the CO-AG Plant were both oversized and expensive to maintain, resulting in the replacement of the entire pump units.
BMW – Inverter & Pump Upgrade (Cont. ) Specialist Project To Reduce Energy Usage With the Paint Shop Facility Detailed Site Survey of All Equipment With High Energy Consumption Full Written Report of Findings With Reduction Proposals Comprehensive Study of Cost Effectiveness of Individual Proposals Customer Agreed Strategy of Achieving Desired Reduction In Energy Installation of Inverter Motor Control To Pumps and Fans Modification of Control Systems To Incorporate Inverter Control Electrical and Mechanical Installation of New CO-AG Pumps Full Update of E-Plan Drawings and Maintenance Documentation