Manufacturing Plant
Faridabad
Production Reporting Accuracy Audit Across PLC and SCADA Layers
Problem: Plant reports were showing different production values across operator screens, supervisory dashboards, and management summaries.
Analysis Performed: We traced the flow of counters, production tags, update timing, and supervisory mapping between the PLC and SCADA environment.
Solution Provided: We identified mismatched tag handling, update-sequence inconsistencies, and reporting-logic gaps, then recommended a cleaner data mapping and validation structure.
Technologies Used: PLC, SCADA, reporting layer
Final Result: The client gained a clearer path to improved reporting accuracy, stronger production visibility, and better trust in plant-level data.
Packaging Unit
Delhi NCR
Alarm and Event Data Verification for Recurring Production Interruptions
Problem: Maintenance teams were struggling with recurring stoppages because alarm history and event records were incomplete or inconsistent across systems.
Analysis Performed: We reviewed alarm flow, event generation, timestamp behavior, and the path from machine-level conditions to supervisory visibility.
Solution Provided: We highlighted alarm-data integrity issues, event-logging gaps, and improvement priorities for synchronization and reporting consistency.
Technologies Used: PLC, HMI, SCADA
Final Result: The plant received a structured plan for stronger fault visibility, better event history, and more useful operational records.
Automotive Supplier
Gurugram
Sensor-to-PLC Data Integrity Review for Quality-Critical Operations
Problem: A quality-sensitive process was experiencing inconsistent readings between field sensors and displayed machine values, creating uncertainty in decision-making.
Analysis Performed: We checked sensor signal handling, PLC mapping, scaling logic, update timing, and operator-side value consistency.
Solution Provided: We documented the accuracy gaps, identified likely causes in the control path, and recommended validation and correction priorities for the affected signals.
Technologies Used: Sensors, PLC, HMI
Final Result: The client gained better confidence in control-layer data and a stronger basis for operational accuracy improvements.
Food Processing Plant
Noida
IIoT and Dashboard Latency Analysis for Real-Time Monitoring Reliability
Problem: Management dashboards were not reflecting plant conditions quickly enough, which reduced trust in remote monitoring and delayed response during active issues.
Analysis Performed: We reviewed gateway behavior, update intervals, synchronization timing, and the route from control systems into the IIoT and reporting layers.
Solution Provided: We identified latency sources and recommended optimization steps for update cycles, synchronization handling, and reporting architecture cleanup.
Technologies Used: IIoT, PLC, reporting dashboards
Final Result: The client received a clear roadmap for improving real-time visibility and reducing delays in operational reporting.
Textile Unit
Manesar
ERP and Machine Data Handoff Review for Batch and Shift Records
Problem: The plant was seeing inconsistencies between machine-generated data and the information reaching higher-level production records.
Analysis Performed: We reviewed the path from machine data generation through control and supervisory layers into business-side reporting structures.
Solution Provided: We documented handoff mismatches, timing concerns, and data-structure improvement priorities for smoother integration.
Technologies Used: PLC, SCADA, ERP/MES interface
Final Result: The plant got a more actionable plan for better reporting consistency and stronger data confidence across operational and business teams.
