Customer Projects
Explore in-depth presentations of innovative Ignition® projects submitted by our customers.
Ignition-Powered UNS Establishes Single Source Of Truth For Aerospace Manufacturer
BMT Aerospace is modernizing its factories for the Fourth Industrial Revolution by combining centralized data collection with innovative software solutions to improve quality and efficiency. With the help of AT-Automation, BMT Aerospace implemented an Industrial Internet of Things (IIoT)-connected Manufacturing Execution System (MES) with a database structured as a Unified Namespace (UNS), establishing a single source of truth across the organization.
8 min video
Ignition-Built CMMS Reduces Cost & Expands Functionality For EV Auto Maker
Lucid Motors replaced a rigid, cost-prohibitive CMMS platform with a solution built entirely in Ignition that not only fulfilled the tasks performed by the previous system, but also allowed for a variety of improvements and enhancements.
6 min video
Ignition-Based Waterway Upgrade Ensures Long-Term Resilience For Adelaide Coastline
The Patawalonga Lake System (PLS) is a 1.6-kilometer man-made waterway designed to protect the Adelaide coastline, from Glenelg to West Beach, from flood risks. Managed by the Department for Environment and Water, the system plays a crucial role in community safety by controlling stormwater surges and tidal events. SAFEgroup Automation (SGA) recently upgraded the PLS, incorporating Ignition to enhance the system with modern automation and real-time capabilities. The key innovations included: Real-time API tidal data for more precise water flow control, enabling dynamic response to changing environmental conditions. Built-in videos to guide operators through the functional description, improving understanding and operational efficiency. A chatbox feature for communicating and recording maintenance work and events, streamlining coordination and documentation. CCTV integration for real-time surveillance, improving system monitoring and security. The ingestion of 20 years of historical data to aid in effective modeling and predictive analysis, optimizing future decision-making. The upgrade ensures faster, more accurate flood protection, better water quality management, and increased operational flexibility, while Ignition enables centralized control, seamless data integration, and scalable future upgrades.
12 min video
Nationwide Ignition Platform Provides Centralized Supervision For Water Provider’s 10 Autonomous Regional Divisions
Veolia has partnered with 2Gi Technologie to modernize and expand its SCADA systems, covering both drinking water distribution and wastewater treatment operations. The project is built on a nationwide Ignition platform, deployed in a scalable, cloud-based architecture that ensures flexibility and future-proofing. The new platform provides centralized supervision for Veolia’s 10 autonomous regional divisions, aggregating data from over 60,000 connected devices operating with a wide range of communication protocols. This unified approach strengthens operational efficiency, improves responsiveness, and enhances data-driven decision-making to better protect and preserve water resources across critical infrastructure in alignment with Veolia’s “GreenUp” sustainability initiative.
9 min video
Ignition-Based Smart Scheduler Reduces Production Hours & Improves Fulfillment Time For Sustainable Packaging Manufacturer
Actemium Toronto developed a smart scheduler in Ignition to provide automatic and algorithmic scheduling for Trioworld North America (TWNA)’s production orders based on defined rules and integration with their ERP.
11 min video
Water District Implements Ignition System To Deliver Increased Visibility, Redundant Communication, And Secure Remote Access
The Wheeler Ridge-Maricopa Water Storage District (WRMWSD) replaced its failing 2000s-era SCADA system with an Ignition 8.1 platform running on Opto 22 groov EPIC controllers and a Canary Historian, delivering sub-second visibility, triple-path redundant communications, and secure remote access. This upgrade eliminated daily communication outages, cut energy use by 8%, and gave operators full real-time insight and predictive-maintenance capability across 34 pumping plants.
9 min video
Steel Producer Achieves Significant Savings With Ignition & Custom Machine Learning Model
ECON Tech’s project addressed the critical challenge of controlling molten steel superheat temperature in a steelmaking plant by implementing a unique solution that integrated Ignition with a custom Machine Learning (ML) model. Developed for Gerdau Corsa’s facility in Tultitlan, Mexico, the system used Ignition as a central hub to integrate disparate signals, track ladle movements, and provide real-time predictive guidance via an intuitive Perspective interface, significantly improving temperature consistency and process efficiency.
7 min video
Ignition-To-Ignition Upgrade Modernizes Oil & Gas Company’s Enterprise System For Peak Performance
EXCO Resources is a leading independent oil & gas company that engages in exploration, acquisition, development, and production of onshore U.S. oil & gas properties. Initially EXCO maintained a templated legacy Ignition 7.9 SCADA system with support from TIGA. After the internal EXCO SCADA team was dissolved, TIGA transitioned into a developmental support role, providing assistance, and guidance to fill the gap. During this time, it became apparent that EXCO was not utilizing Ignition to its maximum potential. Recognizing EXCO as a progressive, forward-thinking organization, TIGA upgraded EXCO’s system from Ignition 7.9 with Vision to Ignition 8.1 with Perspective as the primary production HMI. This upgrade allowed for significant advancements, enabling EXCO to expand beyond the typical confines of a standard SCADA system. TIGA undertook the challenge of developing a dynamic, customizable system that could operate on a global scale and ensure future-proof scalability for EXCO.
10 min video
Fully Automated Distillery Uses Ignition To Integrate SCADA, MES, ERP & Cloud Analytics Into Single Platform
Whiskey House of Kentucky built a fully modern, greenfield distillery with Ignition at the core, integrating SCADA, MES, ERP, and cloud analytics into a single, flexible digital platform. The project enables real-time operations, full barrel traceability, and customer visibility, setting a new benchmark for innovation in custom whiskey manufacturing.
10 min video
Oil & Gas Company Sees Increased Performance, Improved User Experience & Database Optimization With Ignition
CSE ICON (“CSE”) helped Ovintiv design and install an Ignition gateway architecture leveraging its Upstream Accelerator for Ignition as they transitioned from Geo SCADA to Ignition.
9 min video
Enterprise Ignition System Transforms Operations For One Of Australia's Largest Fruit Producers
In the highly competitive agricultural sector, innovation, real-time visibility, and operational efficiency are no longer optional — they are essential for survival. Vide Ultra, supporting various Australian fruit companies, recognized this need for their customer as they expanded their orchard, cold storage, and processing operations across Australia. Following years of growth through a combination of greenfield developments and strategic acquisitions, the client’s operational technology environment had become fragmented, inefficient, and increasingly difficult to scale. Manual processes, siloed systems, and a mixture of outdated HMI and SCADA architectures created significant barriers to achieving operational excellence, quality control, and enterprise-wide visibility. Recognizing the urgent need for modernization, Vide Ultra brought in CanDoIt Solutions to design and deliver a fully integrated operational technology platform. Built on Inductive Automation’s Ignition ecosystem, alongside complementary technologies, the solution was crafted to unify operations from orchard management through to cold storage and high-volume processing. By centralizing data flows across all business layers, CanDoIt Solutions empowered Vide Ultra with a resilient, scalable architecture that delivers: Real-time operational visibility Full end-to-end traceability Performance optimization Data-driven strategic decision-making across the entire enterprise Ignition’s flexibility, rapid development capabilities, and modular approach allowed CanDoIt Solutions to bridge gaps between traditionally siloed operations, creating a future-ready foundation for continued growth and innovation in a highly competitive agricultural market.
9 min video
Academy For Underprivileged Youth Leverages Ignition To Monitor 3D Bionic Prosthesis
Developed exclusively by students at Hebron IT Academy, who are youths from orphaned and underprivileged backgrounds, this project used a combination of Ignition and Arduino-based muscle sensors to train a 3D-printed hand prosthesis. This non-profit project aimed to address a critical gap faced by individuals who have lost limbs due to war or trauma: the long waiting period before receiving a permanent prosthesis. During this time, individuals are at risk of muscle atrophy and lack the opportunity to physically and psychologically prepare for using a bionic limb.
8 min video
Dedicating Valuable Contributions To Improve Ignition And The Community
10 min video
Ignition Provides Advanced Safety and Efficiency Controls At NREL
The Energy Systems Integration Facility (ESIF) at NREL is the United States' premier user facility focused on energy systems research, development, and demonstration. Using the ESIF’s plug-and-play infrastructure, researchers connect electrical, thermal, and hydrogen systems across the facility’s 18 laboratories to create forward-thinking energy scenarios that are secure and reliable. Using Ignition, the facility’s engineers ensure research can proceed safely and efficiently, applying different voltages and frequencies across the labs and preventing dangerous backfeeding of power.
9 min video
Ignition Delivers Process Control & Real-Time Visibility For Global Leader In Aquaculture Feed
A global leader in aquaculture feed aimed to establish its largest shrimp feed production facility worldwide in Guayaquil, Ecuador. To support these growing demands, the aquaculture company needed a modern, centralized system to ensure reliability, efficiency, and full operational visibility for its two major facilities. ASE Global delivered a scalable Ignition-based solution that unified production management, control, and monitoring, creating a standard platform designed to meet current requirements and expand across future local and international sites.
7 min video
Australia’s Busiest Airport Implements Secure & Scalable Ignition Solution With Zero Downtime
Sydney Airport, Australia’s busiest airport, undertook a major Digital Transformation of its legacy Airport Management System (AMS) to a secure and scalable Ignition-based solution, achieving cutover with zero downtime. Designed and delivered by SAGE Automation, the project involved replacing aging SCADA and historian platforms with a new system that integrates with more than 630 field devices. The result is a unified, intuitive system that improves operational visibility and enhances cybersecurity.
11 min video
Unique Ignition Application Assists Family-Owned Paint Manufacturer With Increased Traceability
At Haymes Paint, an Australian paint manufacturer, a specification is a document that describes to their customers the entire scope of a painting project, considering several factors to determine the most appropriate combination of products to be used. The original process of developing specifications was both time-consuming and heavily dependent on specialized knowledge. There were various ways to create a specification by using different templates and painting system combinations. Furthermore, the specifications lacked either clear traceability to the customer or internal specifier, or a formal approval process. SPECPRO, the new, Ignition-based specification application, designed by Insight Engineering, resolved the original processes’ inefficiencies. The application can automate, track, standardize and validate specifications at Haymes Paint with its intuitive interface, reducing the time-cost of generating specifications and clearly indicating a project’s risk factors.
11 min video
PGM Operations Gain Remote Visibility And Increased Cybersecurity With New ASM-Style Ignition System
Concera developed an Abnormal Status Monitoring (ASM)-style SCADA platform in Ignition to replace the existing legacy SCADA systems at Sibanye-Stillwater’s Rustenburg platinum area. The new SCADA encompasses three vertical shafts, 10 air compressors, and various utility areas to enable efficient operation of the system, as well as remote viewing of data and screens from multiple locations.
13 min video
Glass Manufacturer Leverages Hybrid Architecture To Deploy Identical Applications At Multiple Sites
Saint-Gobain Glass mobilized 2Gi Technologie and Plantformance to create and deploy Ignition applications in several countries, within a hybrid architecture of local real-time data and shared data in the cloud. These applications enable Saint-Gobain Glass to have identical applications in its plants to accelerate digitalization and to consolidate data at a global level, as well as leverage data locally for immediate remediation plans stored in Microsoft planner.
9 min video
Infrastructure Provider Builds Demo Platform To Give Clients Dynamic View Of Solutions
Vertiv, an organization that manufactures components and implements automation solutions for data centers and communication networks, used Ignition to create an internal and external demo platform that encompasses all of their go-to market offers and solutions, incorporating both manufacturing facilities and critical regional offices.
10 min video
Edge-To-Cloud Architecture Acquires Real-Time Data From Remote Oil & Gas Facilities
Automation Solutions Ecuador (ASE) developed a cloud-based solution for Smart Energy Applications that enables real-time monitoring, data acquisition, and reporting for Gas-to-Grid (G2G) systems located in remote oil & gas facilities in the Amazon. Smart Energy provides Gas to Grid in a Box (G2G_B) solutions to produce energy using the gas associated with the crude oil extraction process. The G2G_B system uses gas without treatment to reduce carbon footprint. It comprises a generation unit (Waukesha), a control and synchronism unit (Woodward Easygen), and a load shedding unit (Multilin). The project developed by ASE was crucial for Smart Energy to get real-time and historical data of electrical and mechanical parameters, KPIs, and automatic reporting of technical, financial, and environmental results. This allowed Smart Energy headquarters to assess the impact of its solutions. Additionally, the project allowed the solution to be maintained with OpEx instead of CapEx.
5 min video
Power Company Consolidates Diverse Assets With Ignition & Unified Namespace
Dautom successfully addressed the challenge of consolidating diverse power generation assets across multiple geographical areas. By leveraging Ignition as an IIoT platform, implementing Factory Compass 4.0, and the Unified Namespace (UNS) to standardize data models, they achieved operational excellence, resulting in enhanced interoperability and scalability.
10 min video
Automotive Parts Manufacturer Replaces Manual Logging With Fully Automated Ignition System
Murakami’s North American plant produces automotive side-view mirrors, processing plastic into assembled mirrors with included electronics. This project transformed Murakami Injection’s pen-and-paper logging process into a fully Ignition-powered system with automated production, scrap, downtime, and changeover tracking.
9 min video
Electric Utility Expands Ignition System To Oversee Entire Transmission & Distribution Infrastructure
Northern Wasco County People’s Utility District (NWCPUD) had an existing Ignition installation with several projects built by OS Engineering for reporting meter data and operating two hydroelectric power generation projects. To complete their SCADA system, OS Engineering was selected to expand this Ignition installation to include monitoring for over 80 Intelligent Electronic Devices (IEDs) across nine substations. NWCPUD wanted a single SCADA application to oversee all aspects of their transmission and distribution infrastructure, including KPIs and real-time data, along with reporting, alarming, and trending to aid in day-to-day operations.
10 min video
Cloud-Based Control System Delivering Cost-Effective Solutions
Environmental Operating Solutions Inc. (EOSi) designed a reliable, cost-effective control system capable of being deployed quickly for both pilot and long-term projects with a minimal site footprint and impact to operations. Additionally, EOSi aimed to create a user-friendly interface accessible by remote and local personnel.
9 min video
Configurable MES Solution Rapidly Delivers OEE Improvement For Cable Manufacturer
In order to gain more insight into how to optimize line performance, Belden decided to partner with Flexware and utilize their SparkMES™ to rapidly capture and visualize key OEE metrics. This project returned significant ROI for Belden.
11 min video
Island Water Utility Ensures Uninterrupted Service, Improves Compatibility & Scalability
Barbados Water Authority (BWA) implemented a comprehensive SCADA system using Ignition to monitor and manage 55 drinking water stations, nine wastewater stations, and two treatment plants. The project aimed to ensure the provision of uninterrupted and high-quality services while addressing operating system compatibility, scalability, and network issues. Aquatec-Automation designed the SCADA system using the Vision Module for desktop and the Perspective Module for the mobile application.
9 min video
Standardized Interface & Hardware Allow Oil & Gas Company To Rapidly Onboard New Facilities
Edge Controls combined the flexibility of Opto 22 edge devices to standardize field equipment configuration and commissioning with Ignition 8.1, Chariot MQTT Broker, and Perspective, utilizing these standards to rapidly onboard new facilities and provide users with new workflows with a fully mobile-responsive card-based user interface, all while lowering overall costs.
9 min video
Brewery Optimizes Predictive CO2 Model Built in Ignition
Carlton and United Breweries redeveloped an Excel macro- and VBA-driven predictive CO2 model from beer production in Ignition’s Perspective Module. The model shows the predicted amount of liquid CO2 in storage hour by hour over two weeks. The system also monitors key quality and performance indicators in the liquid CO2 system and provides historical capabilities.
8 min video
Global Collaboration Helps Steel Manufacturer Implement Centralized Control Room
The main purpose of Uddeholm, a Voestalpine company, is to manufacture high-quality industrial steel tools, applying best practices for an efficient use of resources and a sustainable development. This strategy has led Uddeholm to become the world’s leading steel tool manufacturer with more than 350 years of innovation and presence in more than 90 countries.
5 min video
All Equipment And Recipes Across 10 Lines Monitored With Single Project
This Ignition project came as a result of a controls-focused project on increasing OEE across 10 packaging lines, specifically monitoring two aspects of production. The first was trending the speeds of each piece of equipment on the line to allow users to monitor the V-Curve over time. The second was maintaining equipment recipe data and tracking when changes were made.
6 min video
Glass Company Increases Profitability With True-North Metrics
HMI Glass was facing numerous challenges impacting profitability, leading to reduced earnings before interest, taxes, depreciation, and amortization (EBITDA) since 2018. The scope of the project was to utilize intelligent manufacturing data to implement a lean management model and drive cultural transformation. The success of the project was tied to fees based on performance and utilized a gainshare model based on a cost of poor-quality improvement.
10 min video
Real-Time Data & Custom Drivers Allow Power Supplier to Anticipate Demand
First Gen is one of the oldest and largest conglomerates in the Philippines that has an interest in power generation and power distribution. While Energy Development Corporation is a diversified renewable energy company, both are under the First Philippine Holdings Corporation – A Lopez Group of Companies, who constantly strive to meet the needs of its customers. In June 2021, the Enhanced Wholesale Electricity Spot Market Design Operations (EWDO) was launched. This officially started the new regulations for shortening of the dispatch interval: instead of a per-hour basis, it was transitioned to a five-minute interval. First Gen and Energy Development Corporation (EDC) have adapted the five-minute interval in their Central Dispatch Operations (CDO). This new regulation was addressed by installing multiple Ignition gateways for faster data monitoring, collection, and secured control of power generation across more than 30+ power plants (and counting). Controtek developed customized drivers to get the real-time dispatch setpoints from the Independent Electricity Market Operator of the Philippines (IEMOP) to meet the demands of the operations and compliance with the new regulation of the EWDO.
12 min video
Digital Troubleshooting Guide Boosts Chemical Company's Efficiency
Cooley Group has a corporate Manufacturing 4.0/Digital Transformation initiative that it is implementing using the Ignition platform. RoviSys was brought on to help guide Cooley Group on this journey and develop the functionalities it needed in a templatized way that promotes scalability and supportability. Cooley Group requested the use of Ignition to develop a Digital Troubleshooting Guide that operators could use to help resolve downtime events impacting their OEE. For this project, RoviSys implemented a creative solution that gave Cooley Group exactly what it asked for, yet made it easy for it to build and configure on its own within the Ignition designer.
3 min video
Water Utility Seamlessly Transitions Operating Systems and Speeds Development
Design and develop a new treatment plant HMI to replace WinCC and condense third-party applications into one platform.
9 min video
Reliable Data Supports Cleaner Energy Initiative For 50 Sites
One of South Jersey Industries’ (SJI) key initiatives is to deliver on its commitment to provide cleaner energy. The generation of renewable natural gas facilities at dairy farms is a key production commitment for SJI. A modular production facility is required at each farm site, near the raw materials. The speed of deployment and number of sites involved demands the establishment of a universal architecture and platform for the integration of control and enterprise systems at the company. In addition, the distributed nature of the system and criticality to the energy infrastructure demand the highest level of security and reliability. Finally, SJI requires that all these sites be centrally monitored from an enterprise SCADA system that will also historize data for financial and regulatory reporting. The central importance of reliable data for continual operational financial justification proves the common Digital Transformation adage that “data is the new gas.” SJI Industries tasked InflexionPoint to build a foundation for the application of key control and information technologies and systems that will allow the organization to realize world-class Digital Transformation and create a secure data pipeline. In doing so, SJI would be able to provide users at all levels of the organization with access to control system information. Through the strategic application of industrial information technologies, significant benefits are realized in the following areas: reliability, availability, visibility, and security. InflexionPoint successfully built and deployed this operational technology stack on Inductive Automation’s Ignition platform, which let ACC establish a scalable architecture to support plants/sites of varying sizes and complexity. The integration of data from the site’s control level, through various secure (DMZ) network layers to the corporate core network and cloud providers, has been addressed.
10 min video
Enterprise SCADA Gives New Zealand Meat Producer Standardized Control
Tamaki Control implemented a new Ignition Perspective standards framework for ANZCO Foods. This framework replaced unsupported SCADA systems and enabled new automation projects and ERP API integration solutions across its 10 manufacturing and processing sites in New Zealand. The project involved upgrading or installing Ignition 8.1 at each site and connecting them on the Gateway Network through an enterprise architecture with the Enterprise Administration Module. The result is a cohesive and efficient system that has positioned ANZCO Foods for continued success.
10 min video
Project Summary:
Initially, Zendal approached Optomation Systems to tackle their needs for monitoring unmanned storage units holding pharmaceutical final products for their customers. When Optomation introduced Ignition, it rapidly evolved into a larger project with a broader scope to encompass the data acquisition of varied equipment, process control and supervision, alarm notification, data historization, and automatic report generation.
The main objective of the project was to implement a system that acts as a data repository for the information collected from the dedicated equipment in the different production areas and auxiliary services, both to satisfy regulatory requirements and prove compliance with CDMO obligations to customers.
In addition, the system integrated new production areas into the system and expanded functionality to include control and supervision of several processes. Field devices and sensors are connected to controllers that execute automated sequences, and from Ignition, operators have full access to the operation, just like a traditional SCADA system.
Problem:
One of the main problems for Zendal was that the freezers and cold rooms for the final products are spread throughout the site and are mostly unmanned, even during working hours. To ensure safety and compliance, set-apart personnel were required to regularly inspect the installations to record data and check for equipment failures.
New products and regulatory requirements also brought in new process units in the form of dedicated equipment (autoclaves, incubators, particle counters, etc.) or skid units with their own data retention mechanisms. This created a labyrinth of data formats, device connections, and communication protocols leading to information silos that were really hard to sort out.
Lastly, the increased production heightened the demand for operations such as connecting skid units or cleaning, which are normally performed manually, to be automated to increase speed, repeatability, and product safety.
Solution:
Selecting the proper architecture design along with Ignition’s unique features, provided the solution for network and area distribution concerns. The hub & spoke architecture with gateway nodes placed locally in each production area ensures that all data collection is independent of the network backbone. Using Ignition Edge in Opto 22’s groov EPIC controllers, combined with Ignition’s Store and Forward mechanism, safeguards historical data in the event of communication problems and guarantees that the central node receives all data for long-term storage.
The system leveraged I/O and programming capabilities of the groov EPIC controllers to achieve the full potential of this segmented design. In practice, each groov EPIC becomes a node in the gateway network that can perform data acquisition, process control, operator interface and data synchronization in a self-contained unit that is independent of the network and other areas.
The gateway network provides the appropriate protection and cybersecurity for data traveling the network backbone, while the physical separation of the IT and OT networks protects all the data sources such as standard laboratory or production equipment with legacy protocols or unsecure access.
For the non-process controlled, unmanned areas, the combination of Ignition’s Alarm Notification and Voice Notification modules provided the perfect solution for the maintenance teams. By monitoring both device alarm contacts and process conditions, the system can provide notifications to selected users using visual elements, e-mail notifications, and in some critical cases, by phone calls to on-duty staff and on-call crews.
By carefully using the unique features of Vision and Perspective, combined with the ability to provide multiple projects within the same license space, the system can easily tackle the different requirements of all its users.
- Operators, production supervisors, and quality technicians gain access to production using screens in Vision clients created for each plant area.
- Managers for production, product, or quality have access to all the plant’s data with Perspective where views were created to unleash the amazing customization of Power Charts, so users can create and save their own charts, check dashboards, or export data for advanced data analysis.
- The Quality Assurance department gets automatically generated and pre-formatted reports for key equipment.
Results:
Besides the evident benefits from going from a manual and non-automated data recollection and supervision to a new and modern automated system, the project also showed the amazing scalability of Ignition.
The extensive use of UDTs to template analyzers and other typical pharmaceutical equipment permitted new equipment to be rapidly incorporated anywhere in the plant, saving time, resources and, ultimately, money. Also, the breakthrough licensing model of Inductive Automation gives the customer the confidence and predictability to keep growing the system.
As a CDMO, Zendal is continuously adapting their installations to its customers’ needs, not to mention that for Zendal and its customers the speed to market is crucial for the business. Ignition’s flexibility and scalability has proved to be the right choice to adapt to Zendal’s ever-changing needs.
Start Date: 11/2020
Deploy Date: Ongoing
Project Scope:
Tags: 187,900 (Atomic Tags), 28,600 (OPC Tags)
Screens: 217
Clients: Unlimited. 5 fixed Vision clients, and other Vision and Perspective clients connect freely
Alarms: 9,500 (Atomic Tags with at least one alarm configured)
Devices used: - 18 Opto22 groovEPIC, 25 Siemens SIMATIC S7-1500, 2 Allen-Bradley CompactLogix, 10 Bürkert Valve Islands (160 Solenoid Valves), 8 Schneider Motor Variable Frequency Drives, and 60 Lighthouse Particle Counter Analyzers
Architectures used: Hub & Spoke
Databases used: Two. One per site, MSSQL Server 2019
Historical data logged: 36,700
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<strong>Website:</strong> <a href="https://www.zendal.com/" target="_blank">zendal.com</a>
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<strong>Website:</strong> <a href="https://www.optomation.es/" target="_blank">optomation.es/en</a>
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Numerous Custom Applications from One Platform for Provider of Gases, Materials, and Equipment
The customer suffered from a classic corporate administrative problem: too many of its critical processes were managed by a hodgepodge of spreadsheets and paper records. Off-the-shelf products solved some of these needs but were too inflexible to be adapted to the custom internal procedures. Ignition allowed custom applications to be built to satisfy these needs and gain wide community acceptance and shape corporate policy and culture.
8 min video
Cloud-Hosted Enterprise SCADA for Large Provider of Aggregate Material and Cement
Dolese Bros. is a large provider of aggregate material and cement throughout the state of Oklahoma. Over the past several years, Dolese has upgraded many of its quarries with advanced automation, networking, and operational systems. A key component of this strategy is the deployment of Inductive Automation’s Ignition platform at each quarry, and then a cloud-hosted enterprise-level Ignition system to provide reporting, visualization, and business system integration at a corporate level. Dolese enlisted the help of Industrial Networking Solutions (INS) to accomplish their goals.
5 min video
Project Scope:
- Tags: 5,801
- Screens: 22 Pages, 50 Views
- Clients: 5 HMI Thin Clients (3 more future scope this year, plus many more for the building expansion project next year), Perspective session via browsers in office
- Alarms: 390
- Devices used: 17 total; Rockwell, Siemens, Delta V; All communications via Kepware
- Architectures used: Redundant, on-site, standard with ability to publish to cloud gateway.
- Databases used: Microsoft SQL Server Cluster and OSI PI in Redundant configuration
- Historical data logged: 4,640 Tags logged in OSI PI Historian
Project Summary:
National Resilience Inc. offers a broad mix of customized manufacturing and development capabilities at their Mississauga, Ontario facility to serve the needs of biopharmaceutical companies at all stages of the drug development process – from pre-clinical development to commercial supply. Resilience requested Grantek’s assistance to develop an Ignition SCADA to support new GMP manufacturing processes in the building area known as the “H-Area.” This solution was needed to rapidly scale a brownfield contract pharmaceutical manufacturing facility, allowing Resilience to maximize their productivity and meet their commercialization goals.
Problem:
National Resilience Inc. offers a broad mix of customized manufacturing and development capabilities at their Mississauga, ON, facility to serve the needs of biopharmaceutical companies at all stages of the drug development process – from pre-clinical development to commercial supply. Resilience requested Grantek’s assistance to develop an Ignition SCADA to support new GMP manufacturing processes in the building area known as the “H-Area.” This solution was needed to rapidly scale a brownfield contract pharmaceutical manufacturing facility, allowing Resilience to maximize their productivity and meet their commercialization goals. With Resilience focused on broadening access to complex medicines, this solution needed to come online as soon as possible. This urgency was heightened as the COVID-19 pandemic and global military conflicts increased the threat to supply chains. Resilience’s clients rely on them to contract and manufacture important pharmaceuticals that help improve and maintain the health of patients across the globe. Ignition SCADA is a vital need to ensure operations function efficiently and these pharmaceuticals are manufactured successfully while maintaining compliance.
Solution:
Grantek reviewed the UX development including the overall look and feel of the Ignition Perspective SCADA user interface with all stakeholders prior to beginning SCADA development. This review was part of the ongoing preliminary engineering engagement. Grantek also suggested milestone design reviews at the 30%, 60%, and 90% stages of the H-Area SCADA development. All functionalities were based on the approved Grantek Functional Specification (FS).
Grantek believes a proper Ignition-centric deployment model should include both an immutable component (verified via digital signature) of the software installation and base-level configuration, as well as a version-controlled mutable component. National Resilience Inc. agreed with this belief and realized the benefit this would provide to their overall operations. To do this Grantek developed the Ignition SCADA application and a new PLC program for direct control of the water valves for the 5 POU stations in the Upstream, Downstream, and Formulation Areas. The new SCADA/PLC coordinates directly with the existing Water Manager PLC (PU70) for Water for Injections (WFI) request/authorization functionality. Grantek also updated the PU70 PLC program to include the new POUs in its water manager prioritization system.
Grantek developed the Ignition SCADA application for direct connection to ethernet enabled OEM equipment and will account for the new SCADA platform will use Ignition across Development, Test, and Production environments, with the Test and Production environments implemented on redundant Ignition gateways. This allows for the solution to evolve in the future, as it could see the three environments be connected to an enterprise-wide cloud-based instance of Ignition. The new SCADA platform supports WiFi distribution as well as data acquisition and monitoring of OEM production equipment and instrumentation. This solution has hardwired connections via the new remote I/O panels for visualization and logging of process values and states. To do this, National Resilience Inc. provided a finalized list of tags per equipment category for integration into the SCADA system. Grantek provisioned a Git-backed version control system to track mutable changes and worked with National Resilience Inc. to define procedures for tracking and approving resource modifications.
Results:
The SCADA solution Grantek provided in the “H-Area” was able to utilize Ignition to not only deliver results, but also integrate with other aspects of the facility. By using a unified software solution like Ignition, National Resilience Inc. also has access to data that can be leveraged in future projects at their other North American facilities. The solution Grantek delivered included over 5,800 tags and 390 alarms. The solution also logged over 4,600 tags in OSI PI Historian. 17 total devices were used in this solution, including Rockwell Automation, Siemens and Delta V – with all communications done via Kepware. Ignition provides a single point of reference for all of their OEM production equipment, no matter the supplier. A redundant, on-site, standard Ignition architecture was utilized, with the ability to publish to cloud gateway. A Microsoft SQL Server Cluster database was selected, including OSI PI in Redundant configuration. While PI is the historian, Ignition is the reporting tool chosen to present that historical data.
Grantek’s solution is helping National Resilience Inc. quickly scale up their unique brownfield contract pharmaceutical manufacturing facility. The result will see National Resilience Inc. produce pharmaceuticals and vaccines available to patients all over the world, especially important as the COVID-19 pandemic and supply chain issues continue to hamper the timely access to needed medications.
Transcription:
00:09
Doug: I'm Doug Yerger, a Principal Engineer with Grantek. Grantek is a systems integrator and a business solution partner with over 40 years of experience in the life sciences, CPG, and food and beverage industries. We are a Premier and Enterprise Ignition Integrator with over 10 years of Ignition experience.
00:30
Doug: We did this project for National Resilience, Inc. Resilience is a technology-focused biomanufacturing company dedicated to broadening access to complex medicines. Founded in 2020, the company is building a sustainable network of high-tech end-to-end manufacturing solutions to ensure that treatments can be made quickly, safely, and at scale. Resilience offers a broad mix of customized manufacturing and development capabilities at its facility in Mississauga, Ontario, Canada. Resilience serves the needs of the biopharmaceutical companies at all stages of the drug development process from pre-clinical development to commercial supply.
01:10
Doug: Grantek helped Resilience develop an Ignition SCADA system to support new GMP manufacturing processes in the building known as the “H-Area.” This solution was needed to rapidly scale a brownfield contract pharmaceutical manufacturing facility allowing Resilience to maximize its productivity and meet its commercialization goals. This SCADA filled the gaps in the new area's automation systems by providing the Water for Injection prioritizing, point-of-use valve control, OEM equipment status monitoring, various environmental and process input monitoring and alarming, alarm statistics, trending of OSI PI data, and reporting.
01:49
Doug: The design tool Figma was used to concept the screens and review with the customer. This is the overview for the Water for Injection system. The upper portion of the page shows the status of the two WFI loops, including their current prioritized queue requests. This page provides the operator and support personnel with key information around the systems so they can more quickly diagnose any issues. On the bottom of the page are point-of-use controls for the point-of-use valves themselves. And in the lower-right corner is a small area that actually is the control for each of the valves. This is a pop-up that is controlled by selecting which area you wish to see.
02:32
Doug: In addition to the overview, the detail of the status of each of the water systems is also available. This provides additional insight into the external water systems, which are not local to the new systems in the H-Area. This is an example of an OEM status screen. Resilience and Grantek work with the OEMs to determine available connectivity methods and available tags. Resilience then combs through those lists to determine which tags they wish to see displayed. This still left a very large number of tags for most pieces of equipment. These tags were then divided into logical groupings, which are displayed as tabs on this page. This page is fully dynamic with all the tabs and tag lists generating automatically from the tag browser.
03:16
Doug: If a tag is added to the directory for a piece of equipment, it will automatically show up on the screen. In addition, the user can pin commonly used tags, which will appear at the top of the page. The lower section is also collapsible to allow for a larger viewing area for the pinned tags at the top. The miscellaneous environmental and process inputs and outputs are displayed by sub-area in the process. This page uses a similar design to the OEM page to provide a better user experience. Once again, this is a fully dynamic page based on the user tag screen. Once again, this is a fully dynamic page based on the tag tree structure. One key addition on this page is the collapsed alarm banner at the bottom of the page. And here is an example showing the alarm banner expanded. P&ID pages are available as well for more detailed troubleshooting.
04:07
Doug: The system includes reporting shown as the alarm report. On the left is the filtering system for the reports allowing you to set start and end date and filter by equipment or alarm name as well as priority and state. The report will update when you click the "Generate Report" button in the lower left. In addition, we have an alarm statistics screen. On this screen, we show the number of alarms occurring over the course of the time period, in addition, the top 10 highest occurrences during that time period as well, showing both the alarm itself, as well as a Pareto showing the ranking of that alarm.
04:46
Doug: A final important feature of this project is the audit trail. We've enhanced the standard audit trail to include previous value, reason, and electronic validation signature when required for audit roll actions. Our workflow for this project made use of the Figma design tool. This facilitated conversations around themes, styles, and user experiences without diving into the development environment. This greatly shortened the design process. I personally think Figma is a great design tool. Resilience's commitment to Ignition is highlighted by this project being expanded for a new greenfield facility, including full control for the WFI and EMS systems. In addition, Resilience is using this project as a basis for a global cloud-based solution.
<strong>Website:</strong> <a href="https://resilience.com/" target="_blank">resilience.com</a>
<strong>Website:</strong> <a href="https://grantek.com/" target="_blank">grantek.com</a>
Improved Monitoring of Power Generators Nationwide
Brown Engineers developed a USA-branded solution specific to their needs for monitoring a nationwide fleet of generators for high-reliability customers.
8 min video
Industry Leader Reduces Paper, Gets Faster Reporting and Better Productivity
This project was created by FG Automação Industrial for Saint-Gobain, a world leader in the design, manufacturing, and distribution of materials and services for the construction and industrial markets. To better attend to their customers' needs, FG Automação Industrial used Ignition Perspective and Sepasoft's OEE Downtime modules. By combining these modules, they were able to transform the Saint-Gobain tube production management process into a robust, user-friendly, dynamic, reliable, and 100% digital interface.
7 min video
New Mobile Capabilities for United Airlines at Houston Airport
In addition to the HMI baggage handling system Vision application running on the workstations for Houston Terminal C/E (and now B), the intent was to offer the same functionality on a mobile device, such as a tablet. While incorporating the same security roles as the Vision application, the operator on the tablet can view/acknowledge/shelve alarms, view graphics, view and interact with device statuses and controls, view statistics and view connection status details from the new Perspective application.
9 min video
Project Scope:
- Tags: 1,322
- Screens: 12
- Clients: 2
- Alarms: 91
- Devices used: 10 Microsoft Tablets with Windows 10 Pro
- Architectures used: Redundant Cloud-Based
- Databases used: Microsoft SQL Express, Microsoft SQL Server Standard, OSI PI Historian
- Historical data logged: 44 tags OSI PI
Project Summary:
This project involved using Ignition in the personalized medicine industry to handle multiple communication protocols in one 21 CFR Part 11-compliant environment. The same regulatory data integrity requirements exist in personalized medicine as in large-scale productions and Ignition has proven to be a valuable tool because of its flexibility, mobility, and above all — device integration.
Problem:
The industry of personalized medicine faces challenges as lab equipment is brought into commercial manufacturing. The equipment consists largely of closed systems that process individual (patient) batches and generate a large amount of GMP data. The equipment is unlike traditional industrial automation equipment, posing a challenge to many different communication capabilities and protocols. The same regulatory requirements, such as 21 CFR Part 11, in large-scale productions persist in personalized medicine, in that data collection and integrity are required for commercialization of the product. Ignition has proven to be a valuable tool with its flexibility, mobility, and above all — device integration — that will serve this industry well.
Solution:
Barry-Wehmiller Design Group chose Ignition because it required a software that could handle multiple communication protocols such as MQTT, OPC UA, and Web Services, all in one environment. Ignition allows users to use portable devices like tablets and laptops, and embedded wall-mounted monitors with web browsers to visualize and interact with the application in clean rooms where traditional HMIs are not ideal because they are difficult to clean and comparatively large. Simple, intuitive screens provide a constant overview of processes, as any minor disruption in an operation can cause a batch to be discarded in cell and gene therapy manufacturing.
Licensing costs were also a major consideration in choosing Ignition over dedicated software designed to perform a single activity, which often have high licensing prices. This level of flexibility allowed Barry-Wehmiller Design Group to develop custom dashboards for each room, along with floor-plan screens that mirror real-world layouts.
Also, Ignition allows for easy integration of a sitewide Active Directory, which directly helps to ensure secure user access to the Ignition application, by maintaining the policies and requirements (such as password requirements, account lockouts, etc.) defined within the Active Directory. Also, Ignition provides a robust audit trail feature which is very important for 21 CFR Part 11 compliance. In addition, the Ignition application was easily validated during IOQ. All of these items help to ensure Barry-Wehmiller Design Group meets and maintains compliance with 21 CFR Part 11.
Results:
Ignition’s ability to work with a variety of technologies was of utmost importance. This was a key factor, because there are so many different types of equipment. The industry is fairly new, and many companies are still developing their processes, and these processes are established in hospitals and universities across the globe. Depending on where a company begins this journey will determine what process equipment it ultimately ends up using in its commercial manufacturing facilities. Ignition’s “multilingual” capabilities made a significant difference in this regard.
The purpose of 21 CFR Part 11 regulations is to ensure that electronic records (and signatures) can be trusted as much as paper records and ink signatures. Cell and gene therapy processes generate many electronic records that are used for regulated purposes and are therefore subject to the regulations. The equipment used in the process, and in-scope of the Ignition PCS, do not utilize electronic signatures, so we are focused on the electronic records, i.e., information in a digital form that is created or used in some way by a computer system. Our Ignition PCS satisfies a few aspects of the regulations pertaining to rendering records, document storage and record retention, system access, authority checks, and audit trails.
<strong>Website:</strong> <a href="https://www.autolus.com/" target="_blank"> autolus.com</a>
<strong>Website:</strong> <a href="https://www.bwdesigngroup.com/" target="_blank"> bwdesigngroup.com</a>
Improvements Beyond Expectations for Global Leader in Beauty & Wellness
This project was developed for a greenfield site, built for the manufacturing of beauty and wellness products. The customer had outgrown their original site and had to expand their production to meet demand. The new site had to provide a solution with improved visibility on their systems, services, and manufacturing processes, and provide consistency in the quality of their manufacturing procedures.
7 min video
Improved SCADA, HMI, and MES for Ninth-Largest Craft Brewer in United States
Stone Brewing is the ninth-largest craft brewing company in the US, located in Escondido, CA, and was founded by Greg Koch in 1996. The goal of the project was to upgrade the existing Siemens BRAUMAT brewing automation system with a new design consisting of Rockwell PLCs, networks, Ignition HMI, historian, batch, and MES software for the two brewhouses at Stone Brewing Company in Escondido, California.
6 min video
Lower Costs, More Data for Australian Water Agency with Over 300 Sites
A regional municipal council has implemented the next generation of remote telemetry monitoring and data-driven decision-making. This represents a significant step for the water industry in Australia and provides access to the same data-driven decision-making process used by large water authorities for a fraction of the cost. Since implementing the new system, the council has seen the commencement of significant cost reductions, improved planning, and data-driven decision-making
7 min video
Global Automotive Machinery Company Gets Single Source of Truth in Every Department
Ignition is used to create a SCADA/MES application that replaces a lot of separate Excel sheets and an old Citect SCADA platform. By using Ignition, AT-Automation instead created a single source of truth for every department (production, process engineering, technical service, quality, logistics) within the company.
7 min video
Enterprise SCADA Streamlines Processes for Renewable Energy
SB Energy engaged Vertech to provide a world-class enterprise SCADA solution for their new remote operations center. They needed a single-platform SCADA system to oversee six solar locations across North America and report industry-standard KPIs and data analytics in real-time.
9 min video
New SCADA and Greater Mobility for Large Water-Management Agency
The evolution of Réseau31 agents' missions requires more and more mobility and access to management and supervision tools using mobile terminals (smartphones, tablets). In addition, the rapid changes in the infrastructure to be monitored and operated (organic changes in the network, maintenance, new contracts, etc.) require frequent changes to the applications.
7 min video
Data from Numerous Processes Aids Large Salmon Producer
This project has been developed by employees at the automation department of Nordlaks Produkter AS for the Nordlaks group. The project consists of several departments where operators can control entire processes and managers can extract information and data all the way down to the component level.
8 min video
Largest Publicly Traded U.S. Water/Wastewater Company Benefits from Enterprise Solution
More organizations are bringing Information Technology (IT) and Operations Technology (OT) together to assist in business decisions at every level of the organization. American Water teamed up with Flexware Innovation and Automated Controls Concepts (ACC) to create an Ignition ecosystem for SCADA/HMI standards, central data collection and analysis, and integration with other backend systems to support data-driven decision-making across the company. This project was the first and largest-scale standardization of their operational technology systems, and consisted of converting an outdated SCADA system to a modern system that is ISA 101-compliant. Ignition Perspective and Cirrus Link MQTT modules were included as key parts of this solution.
9 min video
UK’s Leading Leather Manufacturer Has Better Data, Better Results
The project allows Scottish Leather Group to track rawhides through an intake fridge system, and categorizes these hides based on their food grade, weight, gender, origin and status to intelligently fill the fridge rails. An outfeed selection algorithm helps operators choose the best available hides for a given fridge outfeed job (i.e. lime processing, recirc, etc.).
10 min video
Strong Scalability with the Cloud, MQTT, Mobility & More
The ESM team developed a MQTT fleet management system for a client with systems across Australia. See how Ignition makes cloud scalability a reality.
4 min video
Largest Offshore Oil Operation in Argentina Improves Production
ENAP Argentina has operations in the Austral Basin and the San Jorge Gulf Basin. The Magallanes area has five oil and gas production platforms. It is the largest offshore operation in Argentina. ENAP has an integrated business model based on a strategic management process and projects, whose ultimate goal is to increase the value of the company with safety and responsibility, contributing to the integration and energy supply of Argentina and Chile.
6 min video
Automation Solutions Ecuador
6 min video
Custom ERP Software for a Variety of Businesses
North Point Technology, LLC has created ProFusionSM, a cloud-based, software-as-a-service (SaaS) ERP system designed for small project-based businesses that need all the features of the big brands without the price tag. North Point calls it “ERP for the Rest of Us.”
8 min video
Real-Time and Historical Data Improve OEE
Piedmont Automation chose Ignition SCADA software for visualization and Sepasoft MES software for optimizing OEE downtime in this project for Daimler.
7 min video
Creating a High-Capacity Lab for COVID Testing in Just Nine Months
Ginkgo Bioworks built a new diagnostic sample-processing lab using the Ignition SCADA platform. See how to leverage a modern SCADA system in pharma applications.
7 min video