SCADA

SCADA: Supervisory Control And Data Acquisition. A system that gathers process data from PLCs and other plant-level controllers and provides visualization (ex. KPIs, warnings, alarms and statuses) and intuitive production control to trained operators. The goal is for operators to be able to make better production decisions and troubleshoot more easily, therefore minimizing downtime. SCADA also passes data through to MES.

MES: Manufacturing Execution Systems. How did production take place on a product, by whom, when, with what components and specification metrics? MES documents, manages and stores production processes in real time and historically. For example, tracking and documenting the transformation of raw materials to finished goods, while enforcing product-specific quality compliance rules, and scheduling needed maintenance.

ERP: Enterprise Resource Planning. Business system (Such as  SAP, JD Edwards, NetSuite), manages functions such as the supply chain planning, inventory, work orders, bill of materials, workflow management, production scheduling, manufacturing process, shipping, budgeting, and Inventory

After designing and implementing a competent control system for an application that can supply all the raw data (Orange Level), the integration of the operations of the upper 3 pyramid levels– through relevant data exchange– is Business Intelligence.

SCADA/MES Packages:

The 4 Package options for acquiring raw data and turning it into useful information

• Encrypted Remote Connection: Using an eWON M2M gateway, a non-intrusive outbound fully secure VPN tunnel connection. The eWON uses a private IP address (through the corporate firewall) that is non reachable from the internet. Therefore, there is no need for any IT/firewall changes. This allows remote monitoring by customer, and remote support from FAS. Customer keeps control as VPN connection can be disabled on-site with a button. Full audit trail and traceability connection history report are available to the customer. The router can use a cellular connection where connectivity is limited, or a WIFI connection where a wired connection is impractical.
• Launch up to 5 HMI applications for data monitoring and live equipment control.
• Intuitive zone-based Estop alarm indication for easy identification.
• General Alarm and equipment fault indicators.
• Individual station by station status and error indicators
• Plant overview status trackers.
• Real-time Trends, ad-hoc charts, user friendly data visualization, and spreadsheets.
• Plant-wide status logs in application and exportable to spreadsheet.
• Security, stability, and ease of expandability.

• Level 1 Services
• Robot teach pendant/web services remote access.
• Live monitoring network of IP cameras in each robotic cell through HMI applications.
• Launch an unlimited number of HMI applications with different user roles. Each employee-role sees relevant information and gets access to appropriate controls.
• HMI applications can be launched from smartphone and tablets or any device with a web browser.
• Performance Trackers: Work cell cycle times, Product cycle time, OEE and downtime traceability.
• Pneumatic status for each station is tracked on SCADA application.
• Detailed robot and equipment error codes: Useful for pinning down common downtime issues. Error events are display on screen in detail, and can be exported from database for analysis.
• Historic Alarm logs can be downloaded and archived to formulate preventative maintenance strategies.
• Periodic SCADA reports:  PDF and spreadsheet reports can be automatically generated from HMI displayed data allowing for emailing or archiving.
• Dynamic SCADA reports: generate custom reports on the fly, by using event-driven data to easily filters by hour, day, week, month, as well as by events, and shift.

• Level1 + Level 2 Services
• CCTV system of IP Camera feeds: archiving station operational video history through a dedicated NVR (Network Video Recorder).
• Live and historic energy usage tracking for each power service feed.
• Mobile HMI: a rugged mobile SCADA station minimizes the need for additional stationary HMIs. It features dual cameras, WIFI, GPS, RFID & Barcode scanning, finger print, and clean room options. Operators benefit by using the mobile HMI to quickly address system alarms without wasting production time by walking to a stationary HMI. The maintenance team can use this device for remote troubleshooting, and provide live video sharing for remote access support . Managers find this tool great for production monitoring and during meetings — as dashboards, trends, and custom reports can easily be shared with the production team.
• Admin controls for enhanced shift management: editable call rosters, employee schedule tracking, and employee role based user profiles (to present results appropriate for each persona).
• Custom Alarm notification:  an Email, SMS, or voice notification alarm notification can go to the appropriate party for any desired event.
• Historical trend reporting: historical data turns a database into a high-performance time-series analysis tool. Management has these trends at their disposal to visually reveal patterns of downtime and vulnerabilities in a production strategy.
• Determining root causes: Equipment fault & warning reports, Loss time reasons, Estop reports, starved/blocked conditions, asset utilization trends, and energy consumption reports.
• Recipes: Run equipment more efficiently with custom equipment specific recipes that can be tailored to your production model.
• Equipment maintenance reminders.
• Pneumatic indicators for each actuator is displayed on SCADA application.
• Programmed equipment auto-recovery strategies.
• Integration of 3rd party database and equipment data.
• All project engineering documents archived to webserver.

• Level 1 + Level 2 + Level 3 Services
• Business intelligence: Integrating your Enterprise Resource Planning data (ERP) (Bill Of Materials, Work Orders, resource allocation, scheduling, production costs) with an MES system (production rules enforcement on manual and automated processes, quality control, historical production traceability, and maintenance scheduling) and SCADA (manages and reports Production data,  is the only way of seeing the full picture. The linking of ERP-MES-SCADA results in more effective strategic and operational insights and informed decision-making.
• PLC Redundancy: Standby PLC to takeover sensitive tasks in case of main PLC failure.
• Network redundant ring configuration: Network is configured to reroute packages in the case of a network node failure.
• Live and historic energy usage tracking for each circuit branch.
• Data Cloud backup (amazon services, MS Azure) data, and setting/configuration/ parameter backup / camera video records
• Hosting SCADA/MES application in the cloud
• In lieu of automated production tracking, the reporting of relevant manual production task data to better understand what is happening on the plant floor.
• Track & Trace: Track product genealogy data from the raw materials to the finished state, including consumables and byproducts.
• Machine Learning: apply pattern recognition and computational learning theory in AI to your SCADA operations. For example, machine learning algorithms can process an incoming vision image and compare its metrics with variable ideal product specifications.
• Predictive analytics: minimize downtimes and wasted capital by predicting and forecasting supply, demand, and system availability. Example services include: Predictive maintenance, Predictive downtime, predicting machine settings, Raw material price forecasting, Demand forecasting, and training robots.
• 1 year of FAS support, customization, and upgrades.

    * Requires subscription to MS Azure or AWS cloud services** ISA-95 standard, Enterprise Control System Integration