Challenge
This Client faced challenges with their Excel-based manufacturing execution system (MES), which heavily relied on Visual Basic scripting and separate Excel files for each part number. This approach was prone to data corruption, was difficult to maintain internally, and was limited in scalability and disaster recovery options.
The client’s existing Excel and VBA solution managed metrology and manufacturing data but was vulnerable to errors, data loss, and corruption due to its decentralized nature. Each part number had its own Excel workbook, complicating data aggregation, management, and process improvement analysis. Additionally, data integration from older Cognex cameras using OPC-DA presented technical challenges.
Solution
The team transitioned the Client from Excel to a centralized Ignition Vision platform integrated with a SQL database, ensuring stability, scalability, and ease of data management. The transition included:
- Creating a familiar and user-friendly Ignition interface closely resembling the existing Excel layout, minimizing operator retraining.
- Implementing Ignition scripting for seamless and efficient data handling and integration.
- Employing Ignition’s OPC-DA add-on to effectively gather data from older Cognex camera systems without third-party applications.
- Leveraging the USB keyboard wedge functionality of existing measurement equipment to automate the collection of measurement data.
The success of this project paved the way for additional enhancements and expansions of the Client’s automation landscape. Plans include connecting isolated automation systems into a cohesive, integrated environment leveraging the full capabilities of Ignition, aligning with the Client’s vision for operational excellence and future growth.
The client noted significant improvements in data management, including enhanced ease of analysis and the ability to rapidly generate automated reports.
