Client Overview
A company that produces automotive parts in India with five factories wanted to utilize automation to boost efficiency and observe the overall operation. Yet, the client faced big difficulties because they did not have enough money or any internal knowledge of how to set up the system.
To help, eInnosys recommended a complete FAaaS package for system design, bringing all parts together, and ongoing maintenance.
About the Company
Key Challenges
High Cost Upfront
Automation using traditional methods costs a lot at the beginning, and the client cannot afford it.
Insufficient Expertise
Since there was no team of automation specialists inside the company, someone had to be assigned from another department.
Poor Quality and inefficient reports
The fact that production steps were not connected meant that handmade work had inconsistent results and tended to be inefficient.
Limited Real Time Visibility
Since a centralized HMI, SCADA, and MES system was not present, it became difficult to monitor and decide in real time
Our Factory Automation Services Provided
Turnkey Automation System Design & Integration
For every plant, an automation system was built with the help of robotics, PLCs, sensors, and HMIs tailored to the standards of its operations.
Robotics Integration Services
Used industrial robots for welding, putting pieces together, and preparing products, installing custom EOAT to help in the best performance.
PLC Programming & Upgrades
Created new programs for PLCs and changed out the old ones to make sure that various machines operated smoothly and without interruption.
HMI & SCADA Development
Intuitive screens and main SCADA dashboards were built so that all plant areas could be controlled and observed in real time.
Sensor & Instrumentation Integration
Setup and adjusted these sensors to guarantee better results in robot automation tasks.
MES and IIoT Implementation
Link factory equipment to the cloud via IoT platforms for better predictive maintenance, monitoring in real time, and data analysis.
Remote Monitoring & Support
Kept the systems healthy, solved problems remotely, and updated the software to ensure that there were only small interruptions.
Tech Stack
Automation Hardware : Siemens PLCs, ABB Robotics, Banner Sensors
Software Platforms : Custom HMI/SCADA (Wonderware), Azure IoT Hub, eInnosys MES Suite
Communication Protocols : OPC UA, MQTT
Security : Encrypted VPN tunnels with role-based access controls ensuring secure operations
Business Impact
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