PSIjscada— SCADA solution for the smart factory

Order-related information in the human-machine interface

SCADA (Supervisory Control and Data Acquisition) means the ability to gather and analyse real-time data for monitoring and control of technical processes by means of a computer system. PSIjscada collects information such as concerning defective machine parts, sends it to a central monitoring station and forwards the error message with an escalation assessment. The error situation is represented in a logical overall context. This analysis supports the ongoing control of the manufacturing process:

  • Which current order is affected?
  • How far has the order already been processed?
  • With which quality has the order been processed up to now?
  • How can the current order be re-scheduled to meet the delivery deadline?
  • What other orders are at risk?
  • How can these orders be rescheduled?
  • Which service technician can resolve the error?
  • Is a spare part available from stock?
  • Do we have to call an external technician?
  • When will the machine be ready for use again, according to experience?


Company-wide production process monitoring and controlling

PSIjscada is a scalable tool for collecting and analysing real-time data for monitoring and control of technical processes by means of a computer system. Production topology can be simply modelled and illustrated in line with the layout. The necessary link to automation technology is based on the PSIpenta Machine Data Acquisition system. The resulting overall picture is used for company-wide monitoring and control of all processes that affect production. The solution's functions are above and beyond the now normal human-machine interface (HMI) and supplemented with order-related information. Visualisation can be used to not only display the operating parameters, but also for rescheduling orders, triggering faults manually and displaying material stocks etc.

Data collection and evaluation

The production process link is configurable and based on standard protocols and interfaces (e.g. OPC UA, web services, database interfaces). The collected data (counter, measured values, status information, energy data or product data) can be prepared and linked according to freely definable rules. Historical data provides information on the stability and availability of technical systems in the production process. The evaluation of machine data from sophisticated sensors or the machine control system itself allows targeted analysis of production processes. The focus is on aspects such as plant availability, machine runtime or order-related data such as quantities, times or quality information. The ongoing evaluation of this data supports the continuous improvement process (CIP). Signals from the production system can be used in the Machine Data Acquisition or SCADA application for automated triggering of maintenance measures or for preventive maintenance. The SCADA solution allows the virtual data points to be defined. These respresent a linking of multiple real data sources. This enables more complex correlations of the process and operating data of a plant to be displayed and evaluated.

Individual visualisation

The further development of the SCADA solution goes in two directions:

  • Visualisation of machine data, process data and order data in conjunction with a machine-oriented 2D or 3D-representation of the production plants
  • Illustration of the placement of orders and goods flows in a concrete factory layout

The anticipated future possibility of dynamic reconfiguration of a production system can be explained to the process participants in a simple way. Decoupling the representation of the production system itself from the display of data points enables very flexible visualisations to be generated that are adaptable for different user groups. According to the user's role, information that the respective user needs to fulfil his tasks in the given context is displayed.

Distributed database

SCADA systems work with a distributed database containing data points. A data point contains an input or output value that is monitored and controlled by the system. A distinction is made between physical and mathematical data points: a physical data point represents a measured value, whereas a mathematical point results from calculations from the system condition. Data points typically contain a time stamp to enable historical analysis. SCADA architecture has two different levels: the client level on which the human-machine interaction takes place, and the data server level on which monitoring is performed. The data servers communicate using process controllers with the field devices. The process controllers are connected to the data servers via field buses such as Profibus. In turn, these are connected to one another and to the clients via Ethernet.