On going work involves the automation of ten rotary gas fired furnaces, a flux blending line, a casting furnace, and a delacquering line with an induction furnace. Each rotary furnace is equipped with a hydraulic system to control furnace operation as well as a baghouse for emissions. The furnace burner system is equipped with flame safety and ratio controlled combustion air. All operations are completely automatic, controlled by an Allen-Bradley SLC-5/04 with an HMI application provided for operator interface, trends, reports, and recipe downloads. Originally, a ControlView application was used but it has since been upgraded to RS View. Both discrete and analog control is performed with PID control provided by the PLC. Interface to an RF control is also provided to allow for remote control of the furnace. Originally, communication between the PLC and the operator control station computer was performed by Allen-Bradley Data Highway Plus. This has since been upgraded to a DH+ network interface for the PLC's with communication to the computers through Ethernet via a ControlLogix PLC. At one site, the ControlLogix PLC is also used to operate the delacquering line. The casting furnace is controlled by an Allen-Bradley PLC-5 with a WonderWare HMI. Over 200 projects have been performed since 1995.