Projects / 04
The record does not
sit detached from the screen.
Changing the screens was not enough. Alarm, recipe, and batch record were read from the existing PLC vocabulary.
Project
Production Line SCADA Modernization
On the night shift in the Manisa food hall, the reason for a stop was being hunted on the line. Every signal went red; the batch record sat in a separate report.
We did not write the new SCADA as an empty showcase. Existing PLC tags were read in place. The names the operator already knew were not discarded.
Need
When alarms flood, the line cannot be read.
The request arrived as “new screens.” The real need was that a stop should not be mixed with cleaning.
01
Everything is red
The operator could not separate a real stop from a cleaning window.
02
Batch is detached
Traceability sat in a separate file; filling knew nothing of the record.
03
Tags are scattered
If the new software discarded the old names, the night shift would still hunt for the person who wrote them.
Approach
The existing language is read first.
Architecture was not drawn before the cabinet door opened. Translation started from the operator’s reset.
- 01
Inventory
I/O, alarm, and recipe were written in place.
- 02
Hierarchy
The screen was built at the simplicity the night shift can read.
- 03
Staging
Old and new were verified side by side. The line stayed in production through overlapping stops.
Application
Cabinet, screen, hall.
03 frames
01 / 03
Scope
What locked on this job.
- 01
Existing cabinet and tag inventory
- 02
SCADA architecture and screen hierarchy
- 03
Alarm simplification and access
- 04
Recipe and batch traceability
- 05
Changeover on staged, overlapping stops
On site
The record sits in the control layer.
Recipe change stays on the HMI. Cleaning and production stops do not mix in the same list. The batch does not detach from the PLC vocabulary.
Services
Services used.
- 03Review
PLC & SCADA
Control software must belong to the night shift as well.
- 02Review
Line Automation
A running station is not a running line.
- 05Review
Retrofit
Sound mechanics do not have to be stripped out.
Result
The layer was renewed; the line was not scrapped.
We do not invent reporting speed or an OEE percentage. Delivery is a readable control layer.
Integrated system
SCADA is read from the existing PLC vocabulary.
Commissioned solution
Alarm hierarchy and shift record stayed in production.
Process scope
Recipe, cleaning, and batch sit in the same tag language.
Projects
Talk with the engineering team.
A new line, an existing cell, or an ageing cabinet. Scope comes from the work on your line, not from a catalogue.