Integrated line control and production monitoring for improved efficiency
A home care manufacturing facility in United Kingdom, implemented a new production line to improve operational efficiency and production visibility. The project required centralized control of the line and seamless integration of OEM machines, conveyors, and quality inspection systems.
Contec delivered an end-to-end automation and integration solution, connecting production equipment with the plant’s MOM environment. The system enables synchronized line operation while providing real-time visibility into machine performance, quality processes, and production data for OEE analysis.
Project Highlights:
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Automation of a new home care production line
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Centralized control of conveyors and OEM machines
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Integration of vision-based quality inspection systems
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Standardized communication using PackML
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MOM connectivity for OEE monitoring and production insights
The challenge
Integrating multiple machines into a unified and transparent production line
The production line combined multiple OEM machines, conveyors, and quality inspection systems that needed to operate as a single, synchronized system.
Without standardized control and communication, this setup can lead to inefficiencies and limited visibility into performance.
The main challenge was to coordinate machine logic, interlocks, and material flow while ensuring reliable data collection and integration with the plant’s MOM system for performance monitoring.
Our approach
Delivering centralized control and seamless system integration
Contec implemented a centralized control architecture using a Siemens S7-1500 PLC (TIA Portal V19), acting as the line controller coordinating OEM machines and conveyor systems.
Electrical design, including control cabinets and network architecture, was developed in EPLAN P8, ensuring a structured and scalable setup.
Quality inspection was integrated using Keyence vision systems, enabling automated product verification. Drive control was implemented with Siemens Sinamics G120C drives, including safety functionality.
Machine coordination was achieved through permissive and interlocking logic, with standardized communication interfaces for OEM equipment.
The solution was integrated with the plant’s MOM system using PackML data exchange, enabling consistent machine communication and supporting OEE calculations. Operational data was routed via Kepware, ensuring reliable connectivity between shop floor and higher-level systems.
Operator interfaces were developed in WinCC Unified, providing real-time visibility into machine status, alarms, and production performance.
