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Posted by Nico Mera

Solving Manufacturing Tech Chaos

February 8, 2024

In the intricate landscape of modern technology, industries like manufacturing often grapple with complex systems and interconnected software architectures resembling a perplexing puzzle. In such scenarios, businesses frequently find themselves facing extensive tech platforms with numerous interlinked software components, yet lacking individuals who comprehend these systems or have the bandwidth to decipher them. Enter Hallam-ICS Manufacturing Intelligence - a team of proficient database and application engineers specializing in unraveling, refining, and reconstructing intricate processes within these convoluted systems.

One notable case that exemplifies our expertise involves a client who encountered a recurring challenge. Their existing system relied on fetching recipe information from a database located on a different continent. Unfortunately, this remote database suffered intermittent outages, disrupting production at various sites. During these downtimes, production facilities had to resort to manual workarounds, using locally stored, non-computerized versions of recipes. This manual data loading into Programmable Logic Controllers (PLCs) hindered efficiency and often led to production delays or halts.

Recognizing the urgent need for a robust solution, this client engaged Hallam-ICS to devise a comprehensive approach. We engineered an intermediary infrastructure composed of multiple databases strategically interconnected to ensure seamless operations, even during internet outages. Here's how it unfolded:

Multi-Site Aggregation Database

We created a central aggregation database that acted as a repository, pulling data from the 'source of truth' system located in a different continent. This served as a backup in case of connectivity issues with the remote database.

Site-Specific Databases

Each production site was equipped with its dedicated database, synchronized with the multi-site aggregation database. This ensured that even during internet outages with the remote 'source of truth' system, each site could access and utilize necessary recipe data locally.

Bidirectional Data Flow

To maintain consistency and integrity, we established a seamless data flow architecture. Information traveled from the site-specific databases to the multi-site aggregation database and back, ensuring real-time updates and synchronization with the 'source of truth' system.

Implementing this sophisticated infrastructure led to a remarkable transformation in our client's operational efficiency. What was once a daunting scenario of system downtime causing production bottlenecks became a thing of the past. They now had a reliable, fail-safe mechanism in place that allowed continuous access to critical data, irrespective of connectivity issues with the remote database.

This success story showcases Hallam-ICS's proficiency in navigating intricate tech ecosystems within manufacturing industries. Our tailored solutions not only resolve immediate challenges but also future-proof operations, ensuring smoother, uninterrupted workflows.

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At Hallam-ICS, we understand the complexities within manufacturing systems and excel in orchestrating innovative, scalable, and resilient solutions. If your organization finds itself grappling with similar technological challenges, reach out to us. Let's collaborate to streamline your processes and pave the way for optimized and uninterrupted operations.

Don't let tech complexities hinder your productivity. Embrace the power of intelligent solutions with Hallam-ICS today!

About the author

Nico Mera is the Manufacturing Intelligence Team Lead based in South Burlington, Vermont. With over 3 years of dedicated leadership, Nico has successfully recruited and leads a team of 4 software engineers. His expertise, cultivated over a decade in the SQL Server industry, lies in designing, developing, and deploying cutting-edge software solutions, primarily focused on automating manufacturing processes. Nico's extensive background also includes roles as a Database Administrator and a Software Developer, where he automated processes using C#/.NET and supported SQL and MySQL databases 

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About Hallam-ICS

Hallam-ICS is an engineering and automation company that designs MEP systems for facilities and plants, engineers control and automation solutions, and ensures safety and regulatory compliance through arc flash studies, commissioning, and validation. Our offices are located in Massachusetts, Connecticut, New York, Vermont and North Carolina, Texas and Florida and our projects take us world-wide. 

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Topics: Manufacturing Intelligence

Nico Mera

By Nico Mera February 8, 2024

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