Manufacturing・2025
Automated Production Line Monitoring System
Multiple PLCs integrated with the PowerScada SCADA system to provide plant-wide real-time monitoring and alarm notifications.
CHALLENGE
Challenge
The customer's plant has several production lines with PLCs installed in different years, each running independently. Staff had to go to the line to find out what was wrong, and there was no unified historical data to trace.
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SOLUTION
Solution
With the PowerScada SCADA system at the core, we communicated with PLCs from different brands over Modbus TCP and brought the status of 12 machines together on one monitoring screen.
- A plant floor plan shows running, stopped and fault status in real time
- Faults are pushed to supervisors' phones automatically
- Historical data is written to a database, with daily output and downtime reports generated automatically
EQUIPMENT
Equipment and Technology
- Mitsubishi Q series PLC
- PowerScada SCADA
- Modbus TCP
- SQL Server
RESULTS
Results
- Data from 12 machines integrated
- Fault response time cut by 60%
- Automatic reports from historical data
After go-live, the time from a fault occurring to staff being informed dropped from an average of 15 minutes to under 6 minutes.
GALLERY