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Production Tracking
Capture and present selected production status, counts and manufacturing information.
SCADA, DCS and MES Integration Solutions
SCADA • DCS • MES
From Process Control to Manufacturing Information
Neo Technologies provides engineering and integration services for SCADA, DCS and MES environments that connect industrial control, supervisory monitoring, production information and selected enterprise applications.
Industrial operations generate information at multiple levels. Instruments and machines create field data, controllers execute process and machine logic, SCADA provides supervisory visibility, DCS manages distributed process control, and MES applications use selected manufacturing information for production operations.
SCADA Engineering
DCS Engineering
MES / MOM Integration
Industrial Historian
Alarm & Event Systems
Production Tracking
Traceability
IT / OT Data Integration
PLANT TO ENTERPRISE
Connected Industrial Information Architecture
Integration can connect appropriate information between field equipment, controllers, supervisory systems, manufacturing applications and higher-level information systems.
SUPERVISORY CONTROL
SCADA Industrial Monitoring & Control
SCADA provides operators and engineers with a supervisory view of industrial processes, machines, utilities and distributed plant equipment.
Process Visualization
Equipment Status
Alarm Management
Historical Trends
Operator Interfaces
Reports
PLC Connectivity
DCS Connectivity
Remote Monitoring Architecture
Plant Overview Screens
SCADA project scope can include tag engineering, process graphics, alarm configuration, trend displays, reports, controller communication, historian connectivity and operator interfaces.
DISTRIBUTED PROCESS CONTROL
DCS Engineering & Integration
Distributed Control Systems provide structured control architecture for continuous and process-oriented industrial applications.
DCS engineering can include process-control configuration, controller and I/O engineering, operator graphics, instrumentation interfaces, alarms, trends, sequences, historian interfaces and integration with other plant systems.
Process Control
Controller Configuration
Distributed I/O
Operator Stations
Process Graphics
Alarm Configuration
Sequence Control
Historian Connectivity
MANUFACTURING OPERATIONS
MES Manufacturing Execution System Integration
MES can connect selected production and automation information with manufacturing operations such as work orders, production tracking, quality information, traceability and performance reporting.
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Work Orders
Exchange appropriate production-order information with manufacturing operations.
03
Quality Information
Associate relevant quality and process information with manufacturing activity.
04
Traceability
Capture product, batch, lot, serial and process information where required.
05
Performance Data
Present selected production and equipment performance information.
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Reports
Provide application-specific production, quality and operational reports.
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Plant Integration
Exchange appropriate information with PLC, SCADA and historian systems.
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Enterprise Interfaces
Connect selected manufacturing information with suitable higher-level applications.
CONNECTED ARCHITECTURE
SCADA, DCS & MES Integration Architecture
A structured architecture separates field, control, supervisory, manufacturing and enterprise functions while allowing required information to move between appropriate system layers.
Field Layer
Sensors • Instruments • Equipment
Control Layer
PLC • PAC • DCS
Supervisory Layer
HMI • SCADA • Historian
Manufacturing Layer
MES • MOM • Production
Enterprise Layer
Business & Information Systems
PLANT DATA
Industrial Historian & Data Integration
Industrial historian systems provide a structured layer for storing time-series information acquired from industrial automation and process-control systems.
Time-Series Data
Historical Trends
SCADA Data
PLC / DCS Data
Process Values
Production Information
Reports & Dashboards
MES Data Interfaces
Historian integration can be engineered according to the data sources, retention requirements, reporting needs and interfaces available within the selected platforms.
OPERATIONAL INFORMATION
Alarms, Trends, Events & Reporting
Supervisory and information systems can organize plant data into operator displays, alarm information, historical trends and project-specific reports.
Alarm Management
Configure process and equipment alarms with priorities, messages and operator information.
Historical Trends
Display selected process variables and equipment values over configurable time periods.
Events
Record applicable system and operational events for review and troubleshooting.
Reports
Develop application-specific reports from available process and production information.
INDUSTRIAL DATA CONNECTIVITY
Connecting Control, Supervisory & Manufacturing Systems
SCADA, DCS, historians and MES applications depend on appropriate communication interfaces between plant-floor and information systems.
The integration method should be selected according to the installed platforms, available interfaces, data requirements and project architecture.
Common Integration Technologies
Protocol availability and implementation depend on the specific controllers, software platforms and equipment included in the project.
MANUFACTURING INFORMATION
Production Traceability & OEE Data
MES applications can organize production, quality, traceability and equipment information into a structured manufacturing view.
Production Status
Work Orders
Serial Tracking
Lot / Batch Tracking
Process Data
Quality Information
Availability Data
Performance Data
Production Counts
OEE Information
The exact traceability model and OEE calculation should be defined from the production process, equipment states, quality requirements and available data.
MES FUNCTIONAL AREAS
Manufacturing Operations Information
Production Planning Interface
Selected production-order information
Work Order Management
Orders • Status • Execution information
Production Tracking
Counts • Status • Process information
Traceability
Serial • Lot • Batch • Product history
Quality Information
Inspection • Results • Process data
Performance
Availability • Performance • Quality data
Reports
Production • Quality • Operations
Plant Data
PLC • SCADA • Historian interfaces
APPLICATIONS
SCADA, DCS & MES Applications
The appropriate combination of SCADA, DCS, historian and MES technologies depends on the type of process, production environment and required information flow.
Continuous Process
DCS • Instruments • Historian
Batch Process
Control • Sequences • Production data
Plant SCADA
Monitoring • Alarms • Trends
Utilities
Power • Water • Air • Plant services
Production Lines
PLC • SCADA • MES
Machine Networks
Equipment • Data • Supervisory systems
Traceability
Serial • Lot • Batch information
Plant Historian
Process • Production • Historical data
Energy Monitoring
Meters • Trends • Reports
Quality Data
Inspection • Process • Production information
Production Dashboards
Status • Counts • Performance
Enterprise Integration
Selected manufacturing data exchange
INDUSTRIAL APPLICATIONS
SCADA, DCS & MES Across Industrial Sectors
Control and manufacturing information requirements vary by process, equipment and production environment.
Oil & Gas
Process monitoring, control and operational information.
Chemical
Continuous and batch process-control applications.
Pharmaceutical
Process, production and manufacturing information systems.
Food & Beverage
Processing, production monitoring and manufacturing data.
Automotive
Production lines, traceability and manufacturing information.
Electronics
Production tracking, equipment integration and traceability.
Water & Wastewater
Distributed monitoring, pumping, treatment and SCADA.
Power & Energy
Plant monitoring, utilities and operational information.
Metals & Mining
Process, equipment and material-handling monitoring.
Cement
Process control, drives, equipment and plant monitoring.
Textile
Machine, utility and production-information integration.
General Manufacturing
SCADA, production tracking, historian and MES applications.
ENGINEERING & INTEGRATION
SCADA, DCS & MES Engineering Services
Projects can combine automation engineering, supervisory software, industrial data integration and manufacturing information systems within one coordinated architecture.
Requirement Analysis
System Architecture
Tag Engineering
DCS Configuration
SCADA Development
MES Integration
Historian Integration
Communication Engineering
FAT / SAT
Commissioning Support
PROJECT EXECUTION
Engineering Lifecycle
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Assess
Understand process, systems, interfaces and data requirements.
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Architect
Define control, supervisory and information architecture.
03
Engineer
Develop tags, graphics, controls and integration design.
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Configure
Configure DCS, SCADA, historian and required interfaces.
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Integrate
Connect control, supervisory and manufacturing systems.
06
Test
Perform applicable functional, communication and FAT testing.
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Commission
Support site integration, SAT, startup and handover.
UPGRADES & MIGRATION
SCADA & DCS Modernization
Existing supervisory and process-control systems can be assessed for migration, expansion or integration with newer automation and information platforms.
Modernization strategy should consider existing controllers, I/O, field equipment, operator stations, software, communication networks, historical data and available documentation.
Modernization Scope Can Include
SCADA Migration
DCS Migration
HMI Upgrade
Historian Integration
Network Upgrade
Tag Migration
Graphics Redevelopment
Data Interface Upgrade
PROJECT DOCUMENTATION
Engineering Deliverables
Documentation is prepared according to the agreed project scope and available project information.
System Architecture
Control, supervisory, information and communication architecture.
Tag Database
Applicable process, equipment and information tags.
Alarm List
Configured alarm information according to project requirements.
Screen List
SCADA and operator-interface graphics included in scope.
Network Architecture
Communication topology and system interface documentation.
Interface Definition
Required data exchange between automation and information systems.
Test Records
Applicable functional, FAT and SAT documentation.
Project Backup
Software and configuration backups according to agreed handover scope.
CONNECTED AUTOMATION
Control, Visibility & Manufacturing Information
SCADA, DCS and MES perform different functions. The integration objective is to connect the information required by each layer without treating them as the same system.
CONTROL
DCS & PLC
Process and machine control remain within the appropriate control layer.
VISIBILITY
SCADA & HMI
Supervisory systems provide plant and equipment information to operators.
DATA
Historian
Selected process and production information can be stored for historical use.
OPERATIONS
MES / MOM
Manufacturing systems use appropriate production and operational information.
RELATED SOLUTIONS
Explore Related Automation Capabilities
System Integration Services
Connect PLC, DCS, SCADA, drives, robotics, industrial networks and manufacturing information systems.
System IntegrationProcess Automation
Process control, instrumentation, PLC, DCS, SCADA, control panels and industrial communication.
Process AutomationOEM Machine Solutions
PLC, HMI, drives, servo, robotics, machine vision and connected machine automation.
OEM Machine SolutionsIndustrial Networking
Industrial Ethernet, communication architecture and automation-system connectivity.
Industrial NetworkingPLC Control Panels
PLC, HMI, drive and industrial control-panel engineering for automation applications.
PLC Control PanelsOff-Highway Automation
Mobile controllers, CAN/J1939, HMI, hydraulics, sensors and machine-control integration.
Off-Highway Automation
CONTROL • MONITOR • CONNECT
Planning a SCADA, DCS or MES Integration Project?
Share your existing system architecture, controller details, I/O information, SCADA or DCS platform, communication requirements, production workflow and required manufacturing-data interfaces with Neo Technologies.
Discuss Your Project
FAQ
SCADA, DCS & MES Frequently Asked Questions
What is SCADA?
SCADA is a supervisory control and data acquisition system used to monitor and, where appropriate, control industrial processes and equipment through operator interfaces, alarms, trends and data acquisition.
What is a DCS?
A Distributed Control System is a control architecture commonly used in process applications where control functions are distributed across controllers and I/O systems while being supervised through integrated operator and engineering environments.
What is MES?
A Manufacturing Execution System manages and presents selected manufacturing operations information such as production status, work orders, traceability, quality and performance data.
What is the difference between SCADA, DCS and MES?
DCS primarily performs process control, SCADA provides supervisory monitoring and control, while MES operates at the manufacturing-operations layer using selected production and process information. Their exact functions depend on the platforms and application architecture.
Can SCADA and DCS be integrated?
Yes, when the selected systems provide compatible communication interfaces. The integration method depends on the installed platforms, required data and available protocols.
Can PLC and SCADA data be connected to MES?
Yes. Selected PLC, SCADA and historian information can be exchanged with MES applications when suitable data interfaces are available.
What is an industrial historian?
An industrial historian stores time-series information from automation and process systems so selected values can be reviewed historically and used for trends, reports and other applications.
Can MES support production traceability?
MES applications can support serial, lot, batch and process-data traceability when the required identification and production information is available from the manufacturing process.
Can OEE be calculated from plant data?
OEE can be calculated when the required availability, performance and quality information is defined and reliably available from the relevant production systems.
Can an existing SCADA or DCS system be modernized?
Existing systems can be assessed for migration, expansion or integration. The approach depends on installed hardware, software, field I/O, communication interfaces and project requirements.
Does project scope include FAT, SAT and commissioning?
Depending on the agreed project scope, engineering services can include functional testing, FAT, site integration, SAT, startup and commissioning support.
What information is useful to start a SCADA, DCS or MES project?
Useful inputs include process descriptions, controller details, I/O lists, existing architecture, tag databases, network information, communication protocols, production workflow and required system interfaces.