This major Chrysler plant specializes in producing 2.7-liter and 3.5-liter engines for use in various Chrysler automobiles.

CHALLENGE
Chrysler’s automated equipment and assembly lines were being thrown off-line by “mystery events” 12 to 20 times a year. Plant managers suspected the power supply. Because of the serious impact on productivity, discussions reached the governor’s office, and the utility company was asked to install premium voltage. Utility officials explained that the premium feed could cost millions and would not solve the real problem—voltage sags. We were brought in with utility officials to confirm and address the issue.

SOLUTION
Phase I: Four I-Sense intelligent sensors were installed on the four main electrical branches in the plant to monitor power flow and identify any correlation between sag events and unscheduled downtime. Data collected over a brief test period confirmed that voltage sags were the true cause of the productivity problem.

Phase II: A 100-amp ProDySC battery-free UPS was installed on the 2.7-liter engine head assembly line. This pilot system—applied to one assembly line—would serve as a test of the DySC’s ability to eliminate voltage sags and keep the line operational.

RESULTS
The ProDySC has been running on the 2.7-liter engine head assembly line for more than two years—and during that time, the line has experienced no unscheduled downtime. The other lines haven’t fared as well, maintaining an average of 12-20 events per year.