Selected work and case studies

The challenge was to keep orders, raw materials and finished output consistent throughout the line. The work involved developing a Level 2 system connecting the ERP and PLC, with traceability, production status, operational tickets and downtime records.

Context and constraints

Steel tube production line with machine-level PLC control and integration with business systems.

Intervention

I developed the Level 2 software that acquires ERP orders and coordinates production stages, raw materials and bundles with the PLC. The software reconstructs production progress and state.

Result

Operators and business systems can access order, raw-material and bundle traceability, production progress and state. Operational tickets, events and line downtime records are also available.

Technologies

Node.js Siemens S7 SQL Server MongoDB Real-time Web UI

Replacing the existing SCADA while retaining the plant automation. The work covered analysis and reconstruction of the legacy system, development and validation of the new SCADA, through to the final direct cutover.

Context and constraints

Existing heat-treatment plant with Siemens PLCs, process controllers and a legacy supervision system.

Intervention

I analyzed the legacy supervision components and operational workflows through reverse engineering, then developed and validated the new SCADA. The work includes an event-based state projection model and tracking anomaly handling.

Result

The new SCADA handles recipe management, alarms, historical data and diagnostics after the final direct cutover. The existing plant automation and machine control have been retained.

Technologies

Ignition Siemens S7-300 Siemens S7-1500 SQL Server Industrial protocols

A machine with legacy SCADA and application software needed a gradual modernization path. The work introduced an Edge runtime outside the PLC, providing a basis for migrating application functions progressively.

Context and constraints

Existing industrial machine based on a Siemens S7-300 PLC, with a legacy supervision system and application software.

Intervention

I developed the Edge runtime outside the PLC, integrating machine data and application functions alongside the existing automation. It provides the basis for gradually transferring application functions to more modern software components.

Result

Data acquisition, centralized tag management, commands, alarms and event recording are available in the operational Edge runtime. Application software can evolve incrementally while retaining the PLC control.

Technologies

Node.js Siemens S7-300 S7 communication Edge runtime Real-time Web UI