How Real-Time Monitoring Transformed a Canned Tuna Factory
21/04/2017
Overview
Background
Manufacturing companies often invest heavily in factories and production line equipment, expecting these assets to perform reliably and consistently in order to achieve a positive return on investment (ROI). However, maintaining high operational efficiency and product quality remains a constant challenge. One effective solution is the Production Line Monitoring System, a comprehensive tool designed to optimize production processes and machine utilization.
This system enables manufacturers to track real-time data, analyze performance trends, and visualize key metrics that directly impact production efficiency. By identifying the root causes of downtime, the system empowers decision-makers to take proactive steps that increase output and reduce costly delays. In today’s competitive manufacturing landscape, machinery represents a significant portion of capital expenditure.
System Requirement
The client was facing significant operational inefficiencies while relying on a manual, paper-based OEE (Overall Equipment Effectiveness) system. This approach required extensive labor, incurred high operational costs, and delayed access to critical production data. As a result, management lacked timely and accurate insights across multiple production sites, limiting their ability to make fast, informed decisions.
Operating in the canned tuna industry, where high throughput and strict quality standards are essential, the client identified the need for an integrated, automated solution. Specifically, they required a real-time monitoring and automatic counting system to reduce the dependency on manual checks and improve overall efficiency.
Additionally, they aimed to implement a centralized SCADA (Supervisory Control and Data Acquisition) platform capable of visualizing and recording production data across all factory locations. This would allow seamless data transmission to management, enhancing visibility, responsiveness, and control over production operations from a single dashboard.
Project Implementation
- MIC-7700
- WebAccess/SCADA
- ADAM-6051
- EKI-2828
System Description
To meet the client’s needs for real-time production monitoring and data-driven decision-making, Eforel implemented a Production Line Monitoring (PLM) system using Advantech’s industrial-grade solutions. The integrated system combined powerful edge computing, robust I/O modules, and intuitive SCADA software to deliver end-to-end visibility of the manufacturing floor.
Key components of the solution included:
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Advantech MIC-7700: A compact, fanless, and modularized industrial PC designed for harsh environments. It serves as the local edge computing device, processing high-frequency production data in real-time and supporting high-resolution displays for on-site operators.
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ADAM-6051 Ethernet Remote I/O Module: Connected directly to production machines, this module acts as the primary data acquisition interface. With a 3KHz pulse count rate input, it collects precise, real-time machine data such as product counts, cycle times, and downtime events.
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WebAccess/SCADA: A browser-based supervisory control and data acquisition platform that provides an intuitive dashboard for management and operators. It enables comprehensive data visualization, historical analysis, and real-time alarms.
Once the data is captured by the ADAM-6051, it is transmitted to the MIC-7700 for processing. From there, information is forwarded to WebAccess/SCADA, where it is displayed in real-time dashboards. The system allows factory supervisors and management to monitor operations from any browser-enabled device, whether on-site or remotely, ensuring timely intervention and continuous performance optimization.
By integrating these technologies, the client now benefits from a centralized, scalable, and cost-efficient monitoring system that delivers actionable insights and significantly reduces manual workload.
System Diagram
Conclusion
By implementing Advantech’s industrial solutions through Eforel’s Production Line Monitoring System, the client successfully transformed their manual, paper-based OEE system into a fully automated, real-time monitoring platform. This integration not only reduced labor costs and human error but also enhanced operational visibility, improved production efficiency, and enabled data-driven decision-making across all sites. The solution has laid a strong foundation for smarter, more connected manufacturing.
