ITmatic because of its focused approach has become a leader in providing specialized services to both mining and manufacturing industries some of which have very cyclical sectors by nature. We specifically focused on sectors such as Platinum, Cement, Copper, Glass and Waste Water to name but a few. We have also been exposed to other sectors such as Food & Beverage and even Hydro Power Generation where we have had various successes over the years.
Due to this strong focus we have also become specialist utilizing specific technologies such as Siemens PCS7. From time to time we proactively review and decide in which markets we wish to work, what services we wish to offer and also which products we wish to use. Due to our proactive research and continuous improvement culture we have also introduced unique services associated with consulting and support.
ITmatic experience in Copper
Some of our biggest successes have been in the Copper sector were we have performed work for some of the largest Copper producers in the world and definitely in South Africa. Some of the processes where we were involved includes Pebble and Secondary Crushing, Autogenous Milling, VOD Furnaces, Casting Plant, Copper Filters and Tail Thickeners to name but a few. The services offered included panel manufacturing, PCS7 engineering and commissioning and were a combination of brown and green field's projects and at some times working in conjunction with the plant builders.
ITmatic experience in Cement
In terms of the Cement sector we were fortunate to anticipate the growth in demand for Cement and positioned our selves in this sector quite early in the growth phase going back to our inception into the market place. We at one stage found ourselves doing work for all four of the Cement manufactures in South Africa and even some of their affiliates out side of South Africa. Some of the processes were we where involved includes Pre Crushing, Milling (including the 6.6KV Liquid Starters), Blending, Storage and Packaging to name but a few. The serves offered included consulting, panel manufacturing, cable installation, PLC and SCADA engineering and commissioning. Most of the work involved migrating of Siemens S5 PLC's or in some cases relay logic to modern S7 PLC systems.
ITmatic experience in Platinum
To date ITmatic have been mainly involved in PCS7 engineering services within the Platinum Sector and as of late have become more involved within a consulting and project management aspect to assist with the upfront concept design and budgeting process. Some of the plant areas worked on includes UG2, Merensky and Tailings to name but a few.
ITmatic experience in Glass
One of the very first sectors ITmatic focused on was the Glass sector and has done a great amount of work for two of the major manufactures of bottled glass and also some work with plated glass. In terms of bottle manufacturing we have been extensively involved in all aspects of the process from Batching, Melting (Furnaces), Forming, Annealing up to the Cold End. Some of the services provided included total EPCM project including panel manufacturing, cable installation and engineering to rebuild the entire factory, while others focused on integration of the various OEM equipment. We have also offered extensive support services in this sector along with consulting services. Within this Sector we have mainly leveraged on the Siemens S7 range of equipment.
ITmatic experience with Siemens PCS7
To date ITmatic has completed in excess of 100 projects making use of Siemens PCS7 DCS system. This makes us the largest integrator outside of Siemens Germany of PCS7 projects. The total value of the projects combined exceeds 350 000 IO and consisted mainly out of panel manufacture, engineering and commissioning services. Also interestingly ITmatic was one of the 1st companies to implement PCS7 in South Africa when few standard library blocks existed. We have also won the competition for "Best PCS7 Project" four years from Siemens along with a "Life time achievement" award for our commitment to the product. Presently we are one of the few companies that have implemented V7.0. We have recently developed an effective methodology for migrating PCS7 4.x, 5.x and 6.x to version 7 with least risk to business and hardware replacements.
ITmatic experience Migrating Siemens S5 PLC's
ITmatic has been involved in the various different facets of migrating, the Siemens S5 PLC range of equipment which have now become outdated. These facets include offering consulting services such as HAZOP risk assessments, motivations, compilation of roadmaps and concept designs. Also included are support services such as attending to breakdowns and planned maintenance events. In terms of projects we have converted a number of S5 sites to the newest technologies, mostly under live change over conditions.
ITmatic experience with EPCM projects
Another specialist area for ITmatic is performing Engineer, Procure and Contract Manage (EPCM) projects for our clients. ITmatic is normally involved from the feasibility phase of the project up to commissioning phase. During the EPCM project ITmatic compiles scope of works, standards, concept designs and invitation to tender documents. If required by the client we assist with the adjudication and order placement along with contract management including quality control. One of the largest projects we were involved to manage the overall integration of the project amounted to R75M.
ITmatic experience in MIS/ MES and Integration
We have been fortunate to be exposed to MIS and MES from around 2001 when these were still buzz words. Through this we have learnt when it is best to integrate solutions or to develop a production system based on off the shelf packages. We also understand the complex process including change management to implement solutions within this environment. We have also learnt when a client requires MIS and / or MES as these are vastly different based on specific production process.
ITmatic experience in Live Plant Changes
One area where we have honed our skills are changing over live plants from old to new control systems. Clients are under ever increasing pressures forced to have less and less downtime which makes it very complicated to migrate technologies. Here we have come up with innovative ideas and concepts which assisted us to migrate live plants often resulting in little or no shut down time being required.
ITmatic experience in Dairy, Brewing and Batching
ITmatic have gained extensive experience implementing Dairy, Brewing, Batching and Routing applications and have also been fortunate to receive training 1st hand from Siemens Germany on the S88 standard and implementing of it in the Siemens PCS7 enviroment. We have also gained significant experience using S88 Batch products.
ITmatic experience conclusion
While it may not be stated here ITmatic also has experience in various other sectors of industry delivering specialized services such as huge cable installations, panel manufacturing and specific niche types of engineering applications which are related to specific sectors. Some other examples include "cut to length" control or even complex closed loop control applications.
We constantly strive to be up to date and through this process we proactively identify partners who will compliment our delivery capabilities and to assist with adding value to our clients.