CAI has implemented the integration of data flow from smart sensors, PLCs and SCADA systems into higher level data architectures. Our clients in automotive and discrete manufacturing, food and consumer good production and beyond have implemented better results for their customers using data gathered in CAI-designed intelligent data flow automation processes. These machine control to data centric systems have been used to move data for production and inventory reporting, tracking Key Performance Indices (KPI) as well as the more traditional fault reporting and alarm handling.
Often customers will want selected data points displayed on the shop floor using large LCD screens and/or regularly updated web pages that can be displayed on thin clients / mobile devices. CAI has implemented the traditional “AND-ON” type display systems and newer display to mobile device platforms/thin client.
Example application modules for a Manufacturing Execution System (MES) are:
- Tracking and Traceability for Product and Supply Chain, both specific part and generalized lot information.
- Overall Equipment Effectiveness (OEE), KPI and Downtime Tracking
- Statistical Process Control (SPC)
- Recipe and Changeover Management
Machine Control and Database & Data Collection Platforms Worked with:
PLC/Machine Control Level:
Allen Bradley/Rockwell Compact/Control Logix,
Mitsubishi A and Q Platforms
Some typical projects completed are:
Production reporting from 60 custom built production machines with Mitsubishi A and Q series PLCs into a Postgre backend.
Production reporting from 25 CNC machining lines (Fanuc, Okuma and relay logic-controlled machines) using Mitsubishi PLC as data concentrator into Postgre backend. Discrete, 24VDC signals from each CNC machine.
Interface with inventory management system to pick stored items for outbound shipment in high bay crane AS/RS on command. Rockwell Compact Logix PLC and SQL back end for inventory management system.