MES Integration Eliminated Visibility Blind Spots for Manufacturer
When a US manufacturer needed an MES upgrade, we used AVEVA PI Historian and active RFID tags to enable precise 3D asset tracking and streamlined data flow, boosting reliability, accountability, and delivering ROI within 14 months.
The Project: Improve Operational Visibility Via MES Implementation
When a manufacturer facing visibility problems reached out to E Tech Group, we deployed a modern MES environment to improve operational visibility, streamline work order management, and support data-driven production decisions. By integrating MES modules directly with plant floor assets, our automation solution aimed to deliver real-time performance insights and standardized operational workflows across critical manufacturing processes.
The Challenge: Limited Visibility & Operational Inefficiency
A U.S.-based manufacturing plant struggled with limited visibility into its equipment and asset movements, which were critical for maintaining product quality. The lack of real-time tracking and historical data led to frequent issues and delayed accountability. Equipment utilization and operator performance were also difficult to assess.
The Solution: Integrating Existing Automation Tech with New
E Tech Group engineered an innovative integration of the plant’s existing MES solution with OSIsoft PI and RFID technologies. The solution featured AVEVA PI Historian and a Real-Time Location System (RTLS) using active RFID tags. These tags transmitted Time Distance of Arrival (TDoA) signals, enabling precise 3D location tracking, including acceleration and orientation data. This information was pushed to the Aveva Asset Framework, achieving location accuracy within 1-2 feet.
The Results: Visibility, Reliability, & ROI
The integration significantly enhanced system visibility, asset tracking, and reliability. The improvements met all core requirements and delivered a return on investment within 14 months. This case study highlights how advanced tracking technologies can revolutionize manufacturing operations and ensure product integrity.
This MES system integration transformed raw production data into actionable insights. With real-time monitoring, automated work order tracking, and intuitive dashboards, the manufacturer gained the visibility needed to continuously optimize equipment performance and production planning.
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