Legacy Plant SCADA Modernization

A manufacturing plant had 15 different production lines, each controlled by standalone HMIs. Operators had to walk the floor to check line statuses, and management had no real-time visibility into production numbers or downtime reasons.

Existing Environment

15 isolated PLC systems running legacy hardware and proprietary HMI panels with no ethernet networking.

We upgraded the communication modules on the legacy PLCs, installed a fiber-optic plant network, and developed a centralized SCADA system. The new system aggregates data from all 15 lines into a central control room dashboard and provides management with real-time OEE (Overall Equipment Effectiveness) reports.

• Reduced operator response time to machine faults by 40%.
• Provided management with automated daily production reports.
• Enabled remote troubleshooting for the maintenance team.