Example project · Plastics processing, 12 injection moulding machines from different vendors
Integrating injection moulding machines with ERP
Automatic download of orders from the ERP to the machines and feedback of parts and material consumption, without paper or terminals.
This is an example of the scope I deliver, not a description of a specific client deployment. The figures show typical targets for such a project.
Starting point
Orders from the ERP are printed and carried to the floor. The operator types the order number into the machine by hand and results return to the ERP once a day from a terminal. Three machine vendors, three communication methods, zero consistency.
Solution
One communication service that talks to every machine in its own protocol (Euromap 63 via files, OPC UA, TCP/IP) and exposes a uniform REST interface to the ERP. An ERP order reaches the machine automatically, and parts and consumption come back every cycle. A status panel shows maintenance which machine is online.
Scope of work
- Interface audit of 12 machines and protocol selection
- .NET communication service running as a Windows service
- Mapping orders and confirmations to the ERP format (REST API)
- Queueing and retries when the connection is lost
- Connector status panel and e-mail alarms
- Tag documentation and a service procedure
Other projects
Production tracking and OEE on an assembly line
An MES application collecting parts, downtime and scrap from six workstations, with an OEE report for every shift.
C# / .NET · WinForms · SQL Server · OPC UA
Quality control station with full traceability
A workstation application that guides the operator through inspection, records measurement results and links them to the serial number and batch.
C# / .NET · WinForms · SQL Server · Entity Framework
Migrating machine control from S7-300 to S7-1500
Program migration to TIA Portal, a new HMI panel, cleaned-up PROFINET communication and updated EPLAN schematics, commissioned over a single weekend.
Siemens S7-1500 · TIA Portal · WinCC · PROFINET