Process Industries & Materials
Large-scale SCADA handling tens of thousands of variables and machine-networked MES — validated through replication across multiple group sites.
Industry pain points
- Large units have tens of thousands of variables and alarms; alarm floods bury real anomalies, and operational risk is high.
- Curing and other critical processes are the lifeline of quality; OEM audits require full-process curve traceability.
- Group sites have inconsistent standards, and replication means rebuilding from scratch; in high-temperature, high-pressure continuous processes, data gaps during outages are unacceptable.
Our solution
- Large-scale SCADA and alarm governance on platforms such as ICONICS GENESIS64: chemical-unit-grade delivery with nearly 80,000 variables and 24,000+ alarm points in a single project; alarm classification, reset archiving, event management — real anomalies are not buried, and false alarms stop disturbing operators.
- Machine-networked MES: hundreds of machines networked on the same segment (366 verified); real-time values collected on a 6-second cycle; three-needle process curves retained in full at 14,400 rows per machine per day; barcode ↔ left/right mold ↔ bladder ↔ process curve forward/backward traceability; full MES functions with ERP/PLM/WMS/high-bay warehouse interfaces.
- Outage backfill collection: after a communication outage is resolved, process curves from the interruption period are automatically backfilled — written into the technical agreement as a mandatory clause and passed acceptance.
- Multi-site group replication: pilot site → group-wide rollout (including migration to next-generation PLC platforms); redundant clusters, 7×24 operation, three-year data retention.
Representative projects
- A Taiwan-invested chemical company: two-phase large-scale SCADA for a Bisphenol A unit (temperature control loops / tank farm & dock / energy / alarms).
- A tire group: curing MES covering 366 curing presses, replicated to multiple group production bases.
- A leading optical fiber company: production line HMI with predictive maintenance vibration screens; plus rubber & plastics, coal equipment and new materials MES and smart workshop application practices.
Capability extensions
- SPC statistical process control, energy analysis and predictive maintenance.
- AI process optimization (reserve direction).
Buying scenarios and conversion paths
Target roles
- · VP of production
- · VP of equipment
- · Automation lead
Trigger events
- · Alarm floods on large units
- · Escalating audit and traceability requirements
- · Multi-site group replication needs
Product pilot path
When your product requirements are already clear: start with a 15-minute demo and a small-scale pilot — you can begin with single-line SPC or an outage backfill collection pilot.
Book a Product DemoFull project path
When you only have an industry-level question: start with an on-site diagnosis and a phased proposal. Large-scale SCADA alarm governance, machine-networked MES and multi-site group replication, built in phases.
Request an On-site DiagnosisRelated Anonymous Case
A chemical & tire group: large-scale SCADA and machine-networked MESAlarm governance and curing traceability — start with an on-site diagnosis.
Tell us about your industry and site conditions to get a diagnosis and phased solution proposal.
Request an On-site Diagnosis