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This paper reports on the productivity improvement through two control system upgrades at a manufacturing facility and gives guidance on identifying opportunities to increase production capacity without major capital expenditures. Vintage production equipment built in the sixties and seventies was often designed with large margins to ensure meeting specifications. Mechanical equipment was designed for more then the expected load, burners were selected for more BTUs than required, and material-handling equipment was designed for product-flow in excess of that specified. In practice, the equipment was operated at rates above specified in many facilities increasing throughput until the limiting factor was determined. For the equipment described, upgrading to a modern control systemenabled an increase in the maximum throughput by eight to twenty percent with a very favorable cost/benefit ratio.
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