Moxa serial-to-IP converters on every checkweigher, virtual COM ports into a logger, every reading into SQL Server, a live control chart for the line, and a counting function inside the Siemens WinCC program.
What was wrong
At an instant-noodle plant every pack crossed a checkweigher, and every reading was thrown away. Quality staff had no history and line operators had no live picture of whether a line was drifting.
What I built
Serial-to-IP converters on each scale mapped to virtual COM ports; a logger writing every reading to a central SQL Server; a real-time control chart the line operators watch with the acceptable band shaded; and a historical viewer for quality staff. Plus a production counting system converting raw pack counts to case totals per line, including a function written inside the Siemens WinCC program so totals appear on the plant HMI.
What happened
Rolled out line by line over five years and live in the plant through the last exchange.