REVITALIZING CONTROL: Modernizing Wastewater Treatment Systems
Client Challenge A wastewater treatment plant in North Florida was seeking an upgrade to its aging control systems. The existing setup used an Automation Direct PLC system and an outdated iFix SCADA platform, both of which lacked modern functionality and ease of use. Additionally, the client needed to convert a “black box” OEM-provided Sequential Batch […]
TRANSFORMING TEXTILE MANUFACTURING: Paperless System Delivers Real-Time Insights and Reduced Downtime
Client Challenge A leading textile manufacturer was struggling with the effective monitoring and management of its multiple production systems. Without a standardized interface to visualize real-time plant data, both operators and management faced difficulties in maintaining operational efficiency. Additionally, their outdated HVAC monitoring and alarm system lacked the functionality required for timely reactions to critical […]
FROM MANUAL TO MOBILE: Paperless OEE System Drives Efficiency in Fab Deck Welding
Client Challenge At DSI, we are committed to driving process efficiency through our Paperless Factory Solutions. A longtime client of ours, a leading lawn tool manufacturer, came to us in need of digital transformation of many of its current manufacturing processes. Our client expressed the need for Real-Time Data Access for its Fab Deck Welding […]
CUTTING COSTS, BOOSTING EFFECIENCY: A Paperless OEE System Built for Growth
Client Challenge As a part of our Paperless Factory initiatives for manufacturers, we assisted a long-time client (Lawn Equipment Manufacturer) with a series of digital transformation projects. In this case, our client required a cutting-edge OEE (Overall Equipment Effectiveness) data collection system. Our client expressed that their current Data Collection System was insufficient for their […]
SEAMLESS INTEGRATION: Enhancing Textile Manufacturing
Client Challenge A major textile manufacturer in South Carolina needed ongoing automation support and system upgrades to enhance the reliability, efficiency, and performance of its polyester manufacturing operations. The facility relied on complex automation systems, including Rockwell PlantPAx, MES systems, and various process control elements, and power plant/boiler room controls. In addition to daily automation […]
REVOLUTIONIZING RECYCLING: Automation, Efficiency, & Reliability
Client Challenge A major recycling plant in Las Vegas, NV, needed a state-of-the-art plastics sorting line to improve sorting efficiency, reduce manual intervention, and handle increasing throughput demands. The project required the integration of equipment from 5-10 different Original Equipment Manufacturers (OEMs) while managing the operation of 200-250 motor loads. Additionally, the system needed to […]
FROM OUTDATED TO OPTIMIZED: Seamless Migration of Legacy FactoryTalk Historian to Modern OS and Upgrade
Client Challenge A plastics manufacturer sought to modernize their automation system, which was running on an outdated Windows Server 2003 operating system. The legacy system utilized FactoryTalk View Studio 2.2 for operator interfaces and for data trending, and SQL Server for production data logging to a corporate database. The system supported three operator interface PCs […]
UNIFYING OPERATIONS: Control Room Upgrade for Tobacco Manufacturing
Client Challenge A major tobacco manufacturer sought to modernize and centralize the control systems for their blending and cutting processes. The facility’s existing setup relied on multiple standalone HMIs and SCADA PCs, including PanelView, PanelView Plus, and Siemens Panels. This fragmented system posed challenges in process oversight, troubleshooting, and operator efficiency. Our client required a […]
AUTOMATING PRECISION: Remote Monitoring for Tobacco Processing
Client Challenge A tobacco processing facility in Tennessee required a robust monitoring system for 211 tanks. The system needed to record and report temperature and humidity data for each tank on an hourly basis. Additionally, our client requested the capability to associate batch numbers with each tank when filled, ensuring detailed real-time product tracking and […]
ENERGIZING EFFICIENCY: Ash Handling System Upgrade
Client Challenge A mixed fuel power plant faced ongoing challenges with its existing ash handling system, which had been retrofitted to handle only fly ash after the original system—designed for both bottom ash and fly ash—was modified. The plant’s tertiary filters required constant monitoring, as ash accumulation frequently blinded them, resulting in inefficiencies and increased […]