Case Study · SCADA + SQL
Production Monitoring System
Line-level production tracking with shift targets, live counts, and rejection analysis.
Every hour
Live target tracking
Automated
Defect analysis
+18%
Throughput improvement
Eliminated
Data entry effort
The Problem
What the plant was facing
Shift production was reported at end-of-shift with no way to intervene mid-shift. Rejection reasons were not tracked systematically, and target-vs-actual was calculated in spreadsheets a day later.
Our Solution
What we engineered
- PLC-based cycle counting on each station with rejection reason codes
- SCADA screens showing live target vs actual for each shift
- SQL data model for hourly production and defect Pareto
- Andon-style visual alerts when a station falls behind target
- Automatic end-of-shift email reports
Tech Stack
Hardware & software used
Siemens PLCSCADASQL ServerAndon indicatorsAuto email reports
Gallery
On-site & control room
Similar Project?
Let's engineer yours next.
Tell us about your automation requirement — we respond within one business day.
More Case Studies