NSG Group: Pilkington Automotive Finland Modernizes Legacy Windshield Bending Furnace

NSG Group's Pilkington Automotive Finland modernized a windshield bending furnace to meet evolving production requirements while preserving the process know-how and proven mechanical design developed over decades of operation.

Originally built in 1996, the furnace had undergone several modifications during its lifecycle. However, aging automation technology increasingly limited production flexibility, maintenance efficiency and future development opportunities. To address these challenges, Pilkington partnered with Klinkmann Automation's Machine Intelligence (MI) team to deliver a complete automation modernization with related planning and implementation services.

Modernizing the Automation Platform

The project replaced a legacy automation environment based on Allen-Bradley PLC-5 and SLC 500 controllers, FactoryLink SCADA, PanelView terminals and Data Highway+ communications with modern Rockwell Automation architecture.

The new solution includes ControlLogix controllers, PowerFlex drives, FactoryTalk visualization, a modern recipe-management system and Ethernet-based communications throughout the plant. Existing control logic was migrated to Studio 5000, obsolete hardware was replaced, and the operator environment was modernized while retaining the critical process expertise embedded in the original system.

Supporting Future Production Requirements

The primary objective was to improve the furnace's capability to produce increasingly demanding windshield designs while establishing a maintainable and supportable automation platform for the future.

The modernization delivers:

• Improved production capability for advanced windshield geometries

• Enhanced machine visibility, diagnostics and monitoring

• Greater maintainability and lifecycle supportability

• Better spare-parts availability

• A scalable platform for future process and functionality enhancementsSupporting more advanced production requirements

Why Klinkmann Automation and the Klinkmann MI (Machine Intelligence) Service Team?

Pilkington Automotive Finland had worked with Klinkmann Automation for many years on Rockwell Automation-related projects. In this modernization, Klinkmann played an important role in evaluating alternatives and selecting the most suitable technical solutions.

Klinkmann Automation’s MI team provides services throughout the automation lifecycle, including system design, software development, modernization, migration, documentation, testing, commissioning, training, technical support and continuous lifecycle development.

The team combines strong expertise in Rockwell Automation, Siemens and AVEVA technologies with extensive experience from demanding machine builders and process industry projects. MI specialists support both OEM machine manufacturers and industrial end users in Finland and internationally.

Klinkmann’s MI team has extensive experience in executing automation, digitalization and migration projects for global customers, including complex software conversions, control-system modernizations and international commissioning projects. The team supports customers from concept and engineering through implementation, start-up, optimization and long-term lifecycle services.

For customers, this means access to one experienced partner capable of combining automation expertise, process understanding and international project execution. The result is lower project risk, faster problem solving, improved maintainability and a future-ready automation platform.

A Collaborative International Project

The project was carried out in close cooperation between Pilkington Automotive Finland, Pilkington Mexico and Klinkmann Automation. Together, the teams reviewed process requirements, defined new functionality and addressed technical challenges throughout the implementation.

As with many modernization projects involving nearly 30-year-old equipment, commissioning revealed documentation gaps and legacy-system challenges. Klinkmann's expertise in software migration, Rockwell Automation technologies and commissioning support helped the project team resolve issues efficiently and maintain progress throughout the project.

Project at a Glance

Customer: NSG Group, Pilkington Automotive Finland
Locations: Finland and Mexico
Industry: Automotive Glass Manufacturing
Solution: Complete Rockwell Automation control-system modernization
Delivered by: Klinkmann Automation Machine Intelligence Team
Outcome: Improved production capability, extended system lifecycle and a modern automation platform ready for future development.

Planning a control system modernization, migration or automation upgrade? Contact Klinkmann’s MI team to discuss how we can support your project from concept and engineering through commissioning and lifecycle services.