Scope: Multiline batch automation upgrade, PLC/SCADA revamp, recipe management implementation.

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Project Description

This project involved a comprehensive modernization of the client's multiline batch manufacturing operations. The existing automation system had become difficult to maintain, with fragmented control logic, limited recipe flexibility, and a lack of realtime visibility across production lines. Our team redesigned the batch control architecture to align with current industry best practices, ensuring consistency, reliability, and scalability for future expansion.

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A complete PLC/SCADA revamp was carried out, migrating legacy logic into structured, modular programs on Siemens and Allen-Bradley PLC platforms. The operator interface was rebuilt on AVEVA InTouch HMI, delivering a unified visual experience with improved situational awareness, alarm management, and process diagnostics.

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To further enhance production governance, a modern recipe management system was implemented. This enabled controlled parameter changes, automatic version tracking, and standardized batch execution across all lines. We also integrated traceability modules to record critical process data and events, supporting audits, compliance, and root cause investigations.

Technologies: Siemens/Allen-Bradley PLC, AVEVA InTouch HMI, traceability modules.

Impact: Improved batch cycle time, enhanced traceability, and reduced manual intervention.