Data acquisition and analytics layer with QR code mobility for wire extrusion production lines.
Industry: Manufacturing (Copper Wire)
Quick Facts
| Attribute | Value |
|---|---|
| Customer | United Copper Industries |
| Process | 600 volt building wire extrusion |
| Scale | 10,000 tags (Phase 1), 30,000 tags (full) |
| Development | 11 weeks |
| Integrator | Wunderlich-Malec |
| Mobile | QR code scanning via iPad/iPhone |
The Challenge
Challenge: Implement a centralized and unified way to operate, monitor, and analyze multiple OEM production lines to improve performance.
Specific pain points:
- Multiple OEM production lines extruding various gauges of 600 volt building wire
- No unified monitoring across production lines
- Legacy systems and operator interfaces lacked analytics capability
- Quality Department data in SQL databases disconnected from operations
- Need for mobile access throughout plant floor
Impact: Without centralized visibility, United Copper could not identify areas of production lines where improvements needed to be made.
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Field | Plant PLCs | Existing production line control |
| Data Layer | FrameworX | Data acquisition, reporting, analytics |
| Database | Custom SQL tables | Production data, setpoint audit trail |
| Integration | Quality Dept SQL | Existing data source connectivity |
| Mobile | iPad/iPhone | QR code scanning for device displays |
Technical Features
| Feature | Implementation |
|---|---|
| SQL Data Logging | Production data logged to custom SQL tables |
| Built-in Query Tools | Easy access to production data and reports |
| Setpoint Audit Trail | All changes archived with operator name, client node, previous/current values |
| QR Code Mobility | Each device (drive, motor, control loop) assigned QR code |
| Dynamic Displays | QR scan selects correct display and populates with device tags |
QR Code Mobility Solution
- Each device assigned unique QR code
- Scannable via iPad or iPhone
- SQL query selects correct display for device type
- Populates display with correct device tags
- Provides real-time display anywhere in plant
Automated Reports
- Production reports
- Downtime analysis
- OEE (Overall Equipment Effectiveness)
- Alarm reports
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| PLC Connectivity | Easy connection to existing plant PLCs |
| SQL Database Integration | Quality Department data source connectivity |
| Mobile Client Tools | iPad/iPhone with QR code scanning |
| Built-in Reports | Production, downtime, OEE, alarm reporting |
| Custom SQL Tables | Flexible data logging and audit trails |
| Affordable Solution | Cost-effective analytics layer on legacy systems |
The Results
Reduced Engineering Time — FactoryStudio features kept project organized and limited clutter
Analytics Layer — Created data acquisition and reporting on top of existing legacy systems
Complete Audit Trail — All setpoint changes archived with operator, node, and value history
Mobile Access — QR code scanning provides real-time displays anywhere in plant
Performance Insights — Automated reports uncover areas where improvements need to be made
11-Week Delivery — 10,000 tags implemented, scalable to 30,000 tags
Customer Testimonials:
"Automated reports including production, downtime, OEE, Alarm and more will help uncover areas of the lines where improvements need to be made."
— Fred, Project Manager, United Copper Industries
"Wunderlich-Malec has been terrific to work with on this project. We appreciate their expertise and ability to stay on top of newer technologies to provide longevity, stability, and reliability to our systems."
— Fred, Project Manager, United Copper Industries
Resources:
Download case study: CaseStudy_UnitedCopper.pdf
This case demonstrates production analytics with QR code mobility solution for wire manufacturing operations.
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