SCADA/MES Integration
Production counts, downtime, and OEE, taken from the PLCs you already run.
Plant-floor data from your Siemens and Allen-Bradley PLCs, turned into the screens and reports your team works from. TS Controls is Ignition certified.
Send an RFQ · Office: (877) 524-6674 · Line down? (877) 790-4697, 24/7, subject to personnel availability
- Data
- Counts, downtime, OEE
- Sources
- Siemens, Allen-Bradley PLCs
- SCADA
- Ignition or the one you run
Scope
What a SCADA/MES engagement can include
Start with one line and the questions the plant needs answered, or tie a whole site together. Each engagement is scoped to what the plant needs.
Plant-floor data collection
Machine states, counts, and process values read from the PLCs into one gateway and organized by site, area, line, and machine, so a tag means the same thing on every line. Each controller gets one connection, which every screen and report shares.
OEE and downtime tracking
Run, idle, and fault states come from the PLC. Stop reasons come from the PLC where it knows them and from operators where it does not. Availability, performance, and quality are calculated from the counts the line already makes.
Production counts and reporting
Good and reject counts by shift, line, and part number. Shift, daily, and weekly reports, plus trend screens for engineering.
Recipe, batch, and genealogy, where needed
Recipes sent to the PLC, with a record of who changed what. Batch records. Serial or lot genealogy that ties a finished part to the process data recorded when it was made.
PLC data to business systems, where needed
Counts, downtime, and order data exchanged with ERP and other business systems through a database or a web service. The boundary between the plant network and the business network is agreed with your IT team.
Standards and documentation
Tag naming, screen and alarm standards, and KPI definitions, all written down. Timestamps stay consistent between the PLC, the historian, and the reports, so a daylight-saving change does not shift a shift report. At handover you get as-built architecture drawings, tag lists, and a backup and restore procedure.
Built on
- Ignition
- FactoryTalk View
- WinCC
- OPC UA
- EtherNet/IP
- PROFINET
- SQL database
Ignition is a trademark of Inductive Automation. Other product names are trademarks of their respective owners and are used here only to identify the systems we work on.
Plant levels
Where it runs and what it connects to
We can build it on Ignition, and TS Controls is Ignition certified. Where a plant has standardized on FactoryTalk View or WinCC, we work with the system you have.
Business systems | ERP and other business systems. The engagement covers the interface only: counts, downtime, and order data exchanged through a SQL database or a web service, with the network boundary agreed with your IT team. |
|---|---|
Operations (MES) | OEE and downtime, production counts and reports, recipes, batch records, and genealogy, where the plant needs them. |
Supervisory (SCADA, HMI) | Ignition, or FactoryTalk View or WinCC where a plant has standardized on them: screens, alarms, and trends. |
Control | Allen-Bradley ControlLogix, CompactLogix, PLC-5, and SLC 500. Siemens S7-1200, S7-1500, S7-300, and S7-400. KUKA, FANUC, and ABB robot data, usually through the cell PLC. |
Field | Sensors, I/O, drives, and stack lights. Run, idle, and fault states and part counts start here. |
Networks: EtherNet/IP, PROFINET, and OPC UA. Older controllers on DH+, DH-485, MPI, or PROFIBUS can need a bridge or gateway before their data can be collected. We check that at the assessment. Network details: industrial networks reference. For the screens themselves, see Ignition programming.
How a job runs
How a SCADA/MES project runs
- 01
Assessment
We find out what the PLCs hold today, what the plant tracks by hand, who reads the reports, and what they decide from them. We start with the plant, not a template.
- 02
Definitions and design
Downtime categories, reason codes, OEE rules (what counts as planned downtime, and the ideal cycle time for each part), report layouts, and the system architecture, all agreed in writing before the build.
- 03
Build
The gateway, data model, screens, and reports are built away from production. Where data is missing from a PLC, the change is planned for an outage window.
- 04
Test: FAT and SAT
The factory acceptance test runs with simulated data, and the site acceptance test runs on the live line. Before anyone relies on the numbers, the system’s counts are checked against your manual counts over agreed shifts.
- 05
Commissioning and training
We stay on-site through startup. Operators learn to enter stop reasons, supervisors learn to read and run the reports, and maintenance learns to back up and restore the system. Then documentation and a clean handoff.
New lines, new reports, changes, and troubleshooting. Remote support is available; ask about it. Line down? Call (877) 790-4697, 24/7, subject to personnel availability. We aim to be on site within 4 hours locally and 24 hours stateside, subject to personnel availability.
Why TS Controls
Why TS Controls
One team from the PLC to the report
We program Siemens and Allen-Bradley PLCs, current and legacy. When a count or a stop reason is missing, we can add it in the PLC instead of guessing at it in the SCADA layer.
Ignition certified
TS Controls is Ignition certified, and we can build the SCADA layer on Ignition where it fits the plant.
On-site before we write code
Evaluations happen at the machine, so the first trip is not a guessing trip.
Legacy lines included
A PLC-5, SLC 500, or S7-300 line can report beside a new one.
We don’t inflate scope
Start with one line if that answers the question. You get a written scope sized to the job, not a padded day rate.
Based in Anderson, SC
On-site across the Upstate and nationwide.
From the floor
Answered on The Floor.
- Converting a 1998 cell to IIoT without ripping the PLC — what actually worked
- MQTT Sparkplug vs OPC UA for a hall dashboard — pick one and why
- GSV WallClockTime jumped an hour and our shift report lied
- IT wants the cell on the business VLAN 'for the dashboard' — how do you say no?
- OPC UA explorer that doesn't wreck a production server
- Ignition gateway died on a VM snapshot — lesson so we don't repeat it
Send the line list, the PLCs, and the reports you want.
Upload the packet with the form below or email sales@ts-controls.com. Office: (877) 524-6674. Line down right now? Call (877) 790-4697, 24/7, subject to personnel availability.
Questions
SCADA/MES integration, answered.
What is the difference between SCADA and MES?
SCADA watches and runs the process in real time: screens, alarms, and trends. MES tracks production: counts, downtime, OEE, recipes, and genealogy, and passes that data to business systems. A plant can need parts of both, and the two can share the same data and the same platform.
Can you add OEE to our lines without replacing the PLCs?
Often, yes. OEE needs a run signal, good and reject counts, and an ideal cycle time from each machine. If the PLC already has them, we collect them as they are. If it does not, small PLC changes add them, scheduled for an outage window.
Do we need a full MES?
Not always. A plant can start with counts, downtime reasons, and a shift report on one line, then add OEE, recipes, or genealogy where they are needed. We scope the work to the questions you need answered.
Can the data go to our ERP?
It can, where the ERP has a way in, such as a database table or a web service. We agree the interface, the data, and the network boundary with your IT team before the build.
What should we send with an RFQ?
A list of the lines and machines with their PLCs (make and model), what you track today and how (spreadsheets, whiteboards, or an existing system), the reports you want, and your outage window. Zip the files and upload them with the form on this page (up to 10 MB), or email sales@ts-controls.com.
Request a quote
Tell us what the plant needs to measure.
Send the line list, the PLCs on each line, what you track today, and the reports you want, and we’ll come back with a plan, not a brochure. Line down? Call the 24/7 line, subject to personnel availability.
Office: (877) 524-6674 · 24/7 line-down (subject to personnel availability): (877) 790-4697 · sales@ts-controls.com
New customer? Send us a written, like-for-like quote from another integrator and we'll beat the labor price by 15% on your first purchase order. Excludes emergency line-down work, time-and-materials jobs, materials, and change orders. Final price confirmed in writing by TS Controls.
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