Edge-based calculation engine for real-time KPI reporting with Veracode-compliant security in pharmacy operations.
Industry: Pharmaceutical (Mail Order Pharmacy)
Quick Facts
| Attribute | Value |
|---|---|
| Application | KPI reporting for pharmacy operations |
| PLCs | Rockwell Automation (including custom controllers) |
| Historian | GE Historian 6.0 |
| Database | Microsoft SQL Server (CVS SQL) |
| Clients | 50+ client connections |
| SCADA Nodes | 14 iFix nodes |
| Security | Veracode certified |
The Challenge
Challenge: Modernize legacy SCADA applications for KPI reporting that failed modern security audits (including Veracode) and lacked flexibility for real-time downtime, OEE, and event monitoring.
Specific pain points:
- Legacy applications failed Veracode security audits
- Fragmented system created compliance risks
- Delayed KPI visibility for operations
- Limited scalability for enterprise-wide deployment
- No real-time downtime and OEE monitoring
- Inflexible architecture for pharmaceutical MES integration
Impact: Compliance risks and delayed KPI visibility hindered operational decision-making across pharmacy facilities.
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Field | Rockwell PLCs (multiple) | Production data, custom controllers |
| Edge | FrameworX Edge (App Server 1) | Calculation engine, real-time KPI/OEE |
| Integration | XML Files | Parsed into tags from filter system for MES |
| Historian | GE Historian 6.0 | Time-series data storage |
| Database | SQL Server (CVS SQL) | MES Event Monitor |
| Portal | FrameworX Portal & Monitor (App Server 2) | Dashboards, 50+ clients |
| Legacy | 14 iFix SCADA Nodes | OPC DA client for dashboard |
Edge Calculation Engine
| Calculation | Purpose |
|---|---|
| Downtime | Real-time tracking and categorization |
| OEE | Availability, performance, quality metrics |
| Security Metrics | Compliance monitoring |
| Event Processing | MES event correlation |
Server Infrastructure
| Server | Role |
|---|---|
| App Server 1 | Local Engine + Edge Calculation Engine |
| App Server 2 | Portal & Monitor |
| OS | Windows Server 2021 R2 |
Integration Points
| System | Connection |
|---|---|
| Rockwell PLCs | Direct FS Driver |
| MES System | OPC UA Server (tags published) |
| Filter System | XML files parsed into tags |
| iFix SCADA | OPC DA client |
| GE Historian | Edge → Historian feed |
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| Edge Calculation Engine | Real-time KPI and downtime/OEE calculations minimizing historian overhead |
| Secure Enterprise Deployment | Passed Veracode and modern security audits |
| Templated Asset Types | Rapid deployment with consistent data models |
| Integrated Dashboards | Portal & Monitor with SQL integration for MES events |
| OPC UA Publishing | Tags published for MES system consumption |
| XML Parsing | Filter system data converted to tags |
The Results
- Real-Time KPI Visibility — Downtime, OEE, and security metrics available for pharmacy operations
- Compliance Achievement — Passed stringent security screening and Veracode testing where legacy systems failed
- Optimized Historian Performance — Calculations shifted to edge reduced historian load and improved responsiveness
- Scalable Deployment — Standardized asset templates enable consistent rollout across multiple facilities
- 50+ Client Support — Enterprise-wide dashboard access for operations teams
- Reduced Compliance Risk — Modern security posture eliminated audit failures
This case demonstrates edge-based KPI calculation for pharmaceutical operations with Veracode-compliant security and optimized historian performance.
In this section...
Overview
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