A planned system upgrade securing stable operation in a just-in-time production
For many manufacturing companies, operational stability is not only a question of efficiency – it is essential to maintaining strong customer relationships. This is especially true for order-based, just-in-time production, where even short, unforeseen stops can have a direct impact on delivery performance, costs and reputation.
With this in mind, Cormar Carpets decided to upgrade the control and electronics systems on their production lines.
From technical challenge to business risk
Cormar Carpets operates high-quality production equipment that has proven its durability over many years. From a mechanical perspective, the line was still in good condition and fully capable of running reliably for many years to come.
Over time, however, the electrical and control systems became the limiting factor.
Cormar’s line was increasingly affected by outdated servo drives, PLC hardware and electronic components. Several components and software versions were being phased out, initially leading to higher service costs and later to growing uncertainty around updates, technical support and spare parts availability.
At the same time, instability in the fieldbus systems caused interruptions in communication between individual components. Errors in PLCs and control systems resulted in unforeseen production stops, and each troubleshooting situation led to downtime, idle operators and increased pressure on production planning.
“As an order-driven manufacturer operating just-in-time, it became clear to us that this was no longer only a technical issue. The risk of delays had the potential to affect our ability to meet customer expectations and maintain the strong, long-term relationships we have built over many years,” says Andrew Battersby, Manufacturing Director at Cormar Carpets.
A conscious investment in stability and customer relationships
The decision to carry out a system upgrade was therefore made with a clear objective: to secure a more stable, predictable and future-proof production – and thereby protect Cormar’s high level of service towards their customers.
The upgrade was planned well in advance, with a strong focus on minimizing the impact on daily operations. Production was run to stock, and the planned downtime was scheduled around the Christmas period, when production activity is naturally lower.
Prior to installation, components were assembled, programmed and tested at CAMPEN Machinery. This preparation ensured a controlled and smooth commissioning process without unnecessary surprises. The hardware installation itself was carried out in cooperation with local electricians, while CAMPEN provided technical coordination and support – a flexible setup that can be adapted to each customer’s organisation and resources.
As part of the upgrade, CAMPEN Machinery includes remote access as standard, making subsequent support and troubleshooting significantly more efficient.
One year on: A clear impact on daily operations
Today, one year after the system upgrade, Cormar Carpets is experiencing a noticeable improvement in daily production.
Andrew Battersby summarises the outcome as follows:
“The system upgrade has clearly reduced downtime and improved efficiency. The number of unplanned stops has been significantly reduced, and the line is running more stably and predictably. At the same time, any technical issues that do arise are easier and faster to resolve. For us as a just-in-time manufacturer, the improved stability means better planning, reliable deliveries and further strengthening of customer relationships.”
Planned upgrades instead of unforeseen downtime
The case from Cormar Carpets shows that a system upgrade does not have to result in disruptive downtime. With the right planning, upgrades can be carried out in a controlled manner – often during holiday periods – and with the option to build stock in advance.
The payback period is short but naturally depends on the individual company and production process. However, for order-based manufacturers, even a small number of unplanned stops can quickly exceed the cost of the investment – not only in lost production, but also in customer satisfaction and reputation.
>> Contact us to learn how a system upgrade can be planned and implemented on your production line.