CLIENT
INDUSTRY
SOLUTION
DURATION
The Challenge
Production data was spread across more than 500 PLCs from several different manufacturers, with no common way to see it. Team members and supervisors could not see line status at a glance: machine faults, upcoming tool changes and requests for help were found by walking the floor, and efficiency was only known after the shift. The plant needed one real-time view of production that everyone on the floor, and the supervisors responsible for it, could see.
Key Requirements
- Collect live data from 500+ PLCs from multiple manufacturers
- Show cycle time, production count and efficiency for every machine
- Alert tool changes, machine faults and supervisor calls
- Screens readable across the floor on 75–100 in. TVs
- Plant production status on a web page for key supervisors
The ICR Solution
ICR built a plant-wide production visualization system and andon (visual line-status) on the AVEVA platform. It collects live data from more than 500 PLCs from different manufacturers and turns it into color-coded screens on more than 75 plant-floor TVs, from 75 to 100 inches. Each line screen shows plan, target and actual counts, efficiency and downtime, with a tile for every machine showing cycle time, part count and tool life. Machine faults, tool change alerts and supervisor calls change the tile color the moment they happen, so the right person responds right away. The same production status is available on a web page for key supervisors.
Equipment & Technology
- AVEVA industrial software platform
- 500+ PLCs from multiple manufacturers
- 75+ TVs, 75–100 in.
- Supervisor web dashboard
- Audible alarm horns
Scope of Work
- Up-Front Engineering
- PLC Data Integration
- Network and Data Collection
- Screen Design
- AVEVA Configuration and Programming
- Web Dashboard
- Installation
- Commissioning
Results
The whole plant now runs on one live view of production. More than 75 andon TVs show every line’s counts, efficiency and cycle times in real time, and faults, tool changes and supervisor calls are visible the moment they happen instead of after a walk of the floor. Supervisors see the same status from their desks, so problems get the right response faster and lines stay running 24/7.