A chemical & tire group: large-scale SCADA and machine-networked MES
One is an ocean of variables and alarms; the other a scale battlefield of equipment networking — practices across two extreme scenarios in the process industries.
A Taiwan-invested chemical company (two phases of a Bisphenol A unit) and a tire group (all-steel / semi-steel curing plants) — corresponding to the process industries' two extreme scenarios: alarm governance and equipment networking.
Customer background
A Taiwan-invested chemical company (two phases of a Bisphenol A unit) and a tire group (all-steel / semi-steel curing plants) — two extreme scenarios in the process industries: one an ocean of variables and alarms, the other a scale battlefield of equipment networking.
Challenges
- Chemical units have thousands of variables and alarm floods; real anomalies are buried, and the risk of misoperation is high
- Tire curing is the lifeline of quality; OEM audits require every mold and every cycle's full-process curves traceable
- Hundreds of curing presses networked on the same segment — address planning and data consolidation are heavy engineering
- Continuous production allows no data gaps — process curves from outage periods must be recoverable
Our solution
The solution covers two scenario types: alarm engineering governance for large-scale chemical SCADA, and scale and reliability evidence for the curing-press-networked MES:
- Chemical SCADA · unit-level centralized monitoring with nearly 80,000 variables / 24,000+ alarm points (temperature control loops / tank farm & dock / energy / alarms)
- Chemical SCADA · standardized governance with alarm manager + event list + reset list — alarms are not "popped up" but "managed"
- Tire MES · phase one covers 366 curing presses: curing press → pit PLC → group-control SCADA → MES four-tier link
- Tire MES · 40+ collection points, real-time values on a 6-second cycle; three-needle process curves retained in full at 14,400 rows per machine per day
- Tire MES · barcode ↔ left/right mold ↔ bladder ↔ three-needle curve forward/backward traceability
- Tire MES · full MES functions (plan / execution / material / traceability / process / quality / equipment / reports) + ERP/PLM/WMS/high-bay warehouse/HR interfaces, with standardized data interface specification delivered
- Tire MES · outage backfill collection written into the technical agreement and accepted: after a communication outage is resolved, curing curves from the interruption period are automatically backfilled
- Tire MES · redundant clusters, 7×24 operation, three-year data retention, second-level screen refresh
Results
- Chemical unit alarms standardized; alarm fatigue and missed-alarm risk significantly reduced
- Traceability moved from 1–2 days of record search to minute-level queries; scrap and recall scope narrowed precisely to a single mold and single cycle
- The solution has a replication record across multiple group sites (including migration to next-generation PLC platforms); template reuse reduces repeated design, while specific delivery timelines and costs must be calculated per site boundaries
Technology stack
Project boundaries and replication conditions
- Project boundaries：The implemented scope covers the Bisphenol A unit SCADA; machine-networked MES for Plant A/B semi-steel curing areas, outage backfill collection, traceability and enterprise system interfaces, and group site replication
- Applicability conditions：Large-scale I/O, continuous processes or machine-fleet networking; stable point lists / curve protocols and clear network zoning
- Replication prerequisites：Before replication, confirm point lists / curve protocols, network zoning, master-data associations and the group's unified interface templates
- Not disclosed：Scale figures confirmed by responsible persons must not be presented as technical agreement text; traceability time improvements, scrap or recall benefits may only be described qualitatively
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