Summary: DSI Innovations modernized multiple assembly stations for a leading manufacturer by integrating barcode scanning, torque and angle data acquisition, and control system upgrades. The comprehensive solution enhanced data collection, boosted traceability, and positioned the facility for predictive maintenance and future growth—while minimizing production downtime.
Client Challenge
A leading manufacturer needed to modernize and integrate multiple assembly stations within its existing Ignition system to enhance real-time data collection, traceability, and overall process control.
The project involved replacing outdated PLCs and HMIs, integrating torque and angle data acquisition, and ensuring barcode verification for accurate serial number tracking at various assembly lines.
The tight production schedules and critical role of these assembly stations meant that upgrades had to be carried out during weekends and night shifts, demanding careful planning and execution to avoid extended downtime or production disruption.
Additionally, integrating new hardware and networking solutions had to be done while respecting the plant’s strict operational and safety standards.
Our Solution
Our team executed a comprehensive, facility-wide project covering nine distinct assembly stations, each with unique requirements and configurations.
Key aspects of the solution included:
- Installing and configuring barcode scanners for each station, leveraging Profinet communication to ensure reliable data collection and serial number verification.
- Programming PLCs to incorporate SPDM (Serial Production Data Management) data collection blocks, enabling accurate torque and angle monitoring critical for quality control.
- Upgrading outdated PLCs—ranging from S5 and C7-634DP models to modern S7-1200 platforms—to support enhanced data handling and future expansion.
- Modifying HMIs to incorporate real-time operator feedback, including clear rejection messages for barcode read failures and streamlined troubleshooting.
- Adding CP343-1 Communication Modules and 5-port unmanaged Ethernet switches to expand the plant’s networking capabilities, enabling seamless integration into the Ignition analytics platform.
- Building and installing new network panels tailored to the plant’s design standards, providing a secure and organized framework for the new hardware.
- Adding and integrating torque and angle data from Bosch drivers into the PLCs to support predictive maintenance and comprehensive performance monitoring.
- All installations and commissioning were completed during off-hours (nights and weekends) to maintain full operational capacity during peak production periods.
The Results
- The upgrades delivered real-time performance data and ensured that each station’s barcode verification process worked flawlessly, reducing assembly errors and scrap rates.
- Modernized PLCs and HMIs provided operators with improved visibility into station status, boosting confidence and minimizing manual troubleshooting.
- By integrating torque and angle data into the Ignition system, the facility gained valuable insights to inform predictive maintenance strategies, minimizing unscheduled downtime and extending equipment lifespan.
- The scalable architecture and new networking capabilities positioned the plant for future enhancements and data-driven decision-making.
- Our team delivered the entire project seamlessly, balancing technical expertise with practical installation strategies to ensure minimal impact on daily operations—earning high praise from the client for the project’s speed and effectiveness.
Technology Used:
- Siemens S7-1200 PLCs
- Siemens HMI Panels (7” units)
- Siemens CP343-1 Communication Modules
- Bosch Drivers
- Cognex Barcode Scanners
- SPDM Data Collection Blocks
- Ethernet/IP Switches (5-port unmanaged)
- Ignition
- Custom Network Panels
- Profinet Communication Protocols
