The Challenge
The client operated three production lines across a single facility, each controlled by a mix of legacy and modern PLCs from different vendors. Data was siloed — operators had no unified view of throughput, downtime, or quality metrics across lines.
What We Built
We integrated 14 PLCs using a combination of OPC-UA and Modbus protocols into a centralised SCADA platform. A custom dashboard gave plant managers real-time visibility of:
- Machine status and cycle times across all lines
- OEE (Overall Equipment Effectiveness) per line and facility-wide
- Live alerts for threshold breaches with escalation paths
- Shift and daily historical reports, exportable to PDF and Excel
The Outcome
- Downtime identification improved — issues flagged in under 2 minutes vs. 15+ minutes previously
- OEE visibility drove a 12% improvement in throughput within the first quarter
- Operators adopted the dashboard within one week with minimal training