Case studies

Selected work and case studies

A selection of work on real industrial systems. Some identifying details are omitted for confidentiality.

Level 2 and traceability system for a tube production line

Context: Steel tube production line with machine-level PLC control and integration with business systems.
Problem: Keeping orders, raw materials, production and bundles consistent across the different stages of the line, reconstructing their progress and state while making events and information available to both operators and business systems.
Intervention: Development of a dedicated Level 2 system that retrieves orders from the ERP, communicates with the PLC, and coordinates production status and traceability throughout the line, including operational ticket management and line-downtime recording.
Technologies: Node.js Siemens S7 SQL Server MongoDB Real-time Web UI
Result: An intermediate software layer between automation and ERP that centralizes traceability, production status and operational events, while also providing structured information about line downtime.

Context: Existing heat-treatment plant with Siemens PLCs, process controllers and a legacy supervision system.
Problem: Modernizing the supervision system while retaining the existing automation, rebuilding integration with PLCs, recipes, machine states and process data, and preparing for a direct final cutover from the legacy system to the new SCADA.
Intervention: Analysis and reverse engineering of the legacy system, PLC interfaces and operational workflows, followed by development and validation of the new SCADA. The system includes an event-based state projection model, tracking anomaly handling, recipe management, alarms, historical data and diagnostic tools, culminating in the final replacement of the legacy supervision system.
Technologies: Ignition Siemens S7-300 Siemens S7-1500 SQL Server Industrial protocols
Result: A new supervision system integrated with the existing automation, retaining machine control while making operational information, historical data and diagnostics more accessible.

Context: Existing industrial machine based on a Siemens S7-300 PLC, with a legacy supervision system and application software.
Problem: Modernizing the system progressively without replacing the PLC or carrying out a complete revamp in a single step.
Intervention: Introduction of an external Edge runtime for data acquisition, centralized tag management, commands, alarms and event recording. The architecture allows application functions to be progressively moved from the legacy system to more modern software components.
Technologies: Node.js Siemens S7-300 S7 communication Edge runtime Real-time Web UI
Result: An operational Edge system running alongside the existing automation and serving as the foundation for an incremental machine revamp without replacing the PLC control.

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