We brought in armierproductions to model our packaging line workflow and integrate it with our existing SCADA system. The first month was about getting the data pipeline right — connecting the PLCs on three conveyors to a single dashboard. The team spent the first week on-site mapping every sensor and actuator, then another week configuring the OPC-UA gateway. By week three, we had live throughput numbers and alarm logs that matched what our floor supervisors were seeing manually.
The biggest win was catching a recurring jam on the label applicator. The system flagged a pattern of torque spikes that we had been ignoring as normal wear. After adjusting the timing sequence, the jam rate dropped by about 40% in the following two weeks. That alone justified the integration cost for us.
There were a few hiccups with the Modbus-to-EtherNet/IP bridge on an older motor drive — the documentation was sparse, and the armierproductions engineer had to write a custom mapping table. But they documented it clearly and added it to our maintenance manual. The compliance side was handled well: all wiring and panel changes met CSA C22.2, and the arc flash labels were updated before the system went live.
Overall, the first month showed that the modeling and integration work is solid. The system is stable, the data is accurate, and the floor team trusts the alerts. I would have liked a bit more training time for the shift supervisors, but the remote support has been responsive. We are planning to extend the same approach to the filling line next quarter.