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When one of India’s leading industrial automation companies aimed to unify data communication across diverse systems and devices, they needed a solution that ensured reliability, interoperability, and security — all without complex custom integrations.
AdiLogiX OPC UA emerged as the backbone of their connectivity strategy, providing a robust, standardized communication framework between PLCs, sensors, SCADA systems, and enterprise applications. With its platform-independent architecture, secure data exchange, and seamless scalability, AdiLogiX OPC UA empowered the organization to achieve true data transparency, reduce engineering time, and future-proof their automation infrastructure.
The Client’s Challenges
Challenge
- Disconnected production and utility monitoring across devices and systems
- Manual data collection and reporting, prone to errors
- Multiple vendor systems with no integration, causing inefficiency
- Complex compliance requirements in a regulated environment
- Limited historical data analysis for optimization
Impact on Operations
Delayed response to deviations, resulting in higher downtime
Increased risk of human error and slower decision-making
Inefficient workflows and duplicated efforts across teams
Time-consuming audits and regulatory non-compliance risks
Missed opportunities for process improvement and optimization
Our Approach
We began with a comprehensive plant assessment to understand the client’s existing automation landscape and connectivity needs. This included:
- Identifying critical data points across production, utilities, and equipment for real-time monitoring and analysis (temperature, pressure, flow, batch statuses, environmental conditions, etc.)
- Designing a standardized OPC UA framework to enable seamless communication between PLCs, sensors, SCADA systems, and enterprise applications
- Ensuring secure and compliant data handling, meeting industry standards and regulatory requirements
- Planning integrations across multiple vendor devices and with the client’s MES, ERP, and analytics platforms
- Defining KPIs to track improvements in data visibility, operational efficiency, and decision-making post-deployment
Results Achieved
Benefit
Respond to deviations 30% faster with real-time OPC UA data
See the whole plant at a glance with centralized visibility across all systems
Simplify compliance with automated reporting and secure data handling
Ensure consistent product quality through accurate, synchronized monitoring
Make smarter decisions with actionable insights from unified historical and live data
Impact
Minimized downtime and avoided costly production losses
Streamlined collaboration between production, maintenance, and QA teams
Reduced audit preparation time by up to 70%, freeing staff for value-added tasks
Fewer deviations and rejections, improving overall efficiency
Identified opportunities to optimize processes, energy, and resource use
