KEPServerEX & OPC Router: 3 Real-Life Examples of Symbiosis in Production
In October, Inray andPTC (Kepware) hosted a joint webinar. They presented three case studies of customers taking advantage of the KEPServerEX machine data acquisition software and the OPC Router data connector, as well as their joint synergies. The two platforms have enabled these customers to increase their production efficiency and machine uptime. The customers have also used these tools for remote and predictive maintenance.
Inspiring Case Studies for Everyone
This stimulating one-hour webinar in English is recommended for those who:
Already use the OPC Router data connector and the KEPServerEX platform and want to expand their horizons
Are considering starting to collect datafrom machines and taking the overall digitalisation of their company to the next level
Don't have time to watch the webinar? Spend a few minutes reviewing the key information and diagrams of each solution.
Case Study 1 - SAP and PLCs in the Spotlight
Integration of SAP and PLCs at a Manufacturer of Components for Cars Delivered to the Customer in JIT and JIS Modes
The challenge: To link SAP and various types of PLCs to automate production, monitor data transfers and ensure transparency of production processes. The manufacturer needs to ensure fast data exchange between its ERP and manufacturing systems as it is a Just In Time and Just In Sequence production model for premium automotive customers.
The solution: KEPServerEX is used to connect to the controllers (e.g. Siemens), while OPC Router provides data integration among SAP, SQL servers, label printers and other systems. Bi-directional communication supports synchronous communication between SAP and the PLCs, allowing immediate confirmation of operations and feedback to the ERP.
The result: Production efficiency and quality has improved. Manual data entry and error rates have been reduced. Production has been optimised based on the data obtained.
Interesting fact:The solution uses a native interface to SAP, using certified SAP libraries for communication via RFC and IDOC. This enables bi-directional and synchronous data exchange, where SAP immediately knows whether production parameters have been successfully entered into the PLCs, ensuring accurate and timely coordination of production processes.
Case Study 2 - JSON, MQTT and the Cloud in the Spotlight
Predictive Maintenance and Production Optimisation for a Machine Manufacturer
The challenge: To implement intelligent maintenance and production optimisation by collecting data from a wide range of sensors and devices to improve product quality and increase the efficiency of production processes. The manufacturer focuses on monitoring key parameters such as temperatures, pressures and other physical variables that affect the quality of metal part finishes. This data needs to be securely transmitted to a cloud-based application for further processing.
The solution: KEPServerEX provides connectivity to various sensors and control systems (e.g. via Modbus and OPC UA), while OPC Router structures and prepares the data in JSON format for sending to an MQTT broker and then to the Azure IoT Hub. The data is analysed and visualised in real time, enabling rapid response to deviations from the norm, and is also used for remote and predictive maintenance.
The result: Standardised data collection has provided insight into actual machine utilisation and monitoring of the machines in real time. This has made data available for other advanced technologies, including predictive maintenance.
Interesting fact: OPC Router uses the Multi Data Change Trigger feature, which allows hundreds and thousands of variables to be monitored and responded to in one setting. This greatly simplifies configuration and increases the speed of data transfer to cloud systems.
Case Study 3 - SAP and SQL Server in the Spotlight
Increasing Availability and Quality in the Production of Chainsaws, Tools and Garden Equipment
The challenge: To improve production efficiency and quality by automating data collection from production lines and optimising documentation. The company needs a secure solution that will allow rapid changes to production parameters during frequent changeovers to different models, including switching between different types of cutting and CNC machines.
The solution: KEPServerEX connects a wide range of devices (Siemens S7, CNC machines and Fanuc and KUKA robots) and provides data to OPC Router, which then integrates the data with the local SQL Server and the SAP ERP system. The system provides real-time data collection and automatic sending of information on production parameters and performance to databases for subsequent analysis and traceability.
The result: Seamless integration of SAP with production lines and traceability of production parameters and quality indicators for each product. Improved security and speed of communication. The system supports rapid changeovers of production models and variants.
Interesting fact: Each production line has its own SQL Server for local storage of production data, allowing it to operate independently of the central system in the event of a network failure.
KEPServerEX and OPC Router Are a Team. Why Should You Let Them Do the Job for You?
In the case studies above, you can see the possibilities of integrating both products in different industrial environments where scalability, secure communication between systems and perfect visibility into what is happening in production are key factors.
The combination of OPC Router and KEPServerEX offers a complete solution for industrial automation and enables the interconnection of different systems. Thanks to these tools, high levels of machine availability, efficiency and flexibility will become a daily standard in your company.
Are you interested in the case studies and would you like to see short demonstrations of individual solution configurations? Watch the webinar (60 minutes).
