Manufacturing Intelligence

Process Control and Plant Automation  >> Manufacturing Intelligence


Database Design and Integration

Historian Installation and Configuration

Application Development

Reports and Dashboards

Data Analytics

Our Expertise

Microsoft SQL Server

Microsoft Power BI

Visual Studio Applications

Ignition by Inductive Automation®

OSIsoft PI System

Rockwell Automation & GE Digital


Improved Productivity

Manufacturing Visibility

Higher Throughput

Increased Profitability

Make Better Decisions

Learn More About Our Manufacturing Intelligence Services

What is Manufacturing Intelligence?

This high-level overview on Manufacturing Intelligence (MI) is intended for all persons involved in the data stream, including: Automation Engineers, Plant Managers, Data Analysts, and engineers involved in Continuous Improvements and EH & S.

Part 1 - What is Manufacturing Intelligence?

Part 2- Data Sources And Transactions For Manufacturing Intelligence

Part 3- Manufacturing Intelligence - Data Storage

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Manufacturing Intelligence: Make Better Decisions Using Your Data

Manufacturing Intelligence (MI) enables you to see the trends and improve outcomes with the power that data brings. It helps to answer the important questions:

  • What is happening on your plant floor today?
  • How efficient is your equipment?
  • What are the reasons for production downtime and waste?
  • What reduces productivity and where can you make improvements?

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Manufacturing Intelligence Outlook

The future of Manufacturing Intelligence is changing very rapidly and therefore, our team will need to adapt to these future technologies in order to offer our customers the best tools to do their jobs efficiently. Here are a few new technologies that will help us capture, analyze and display data in whole new ways.

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Choosing the Right Database Type for Manufacturing Intelligence

When selecting a database type it is important to address the user requirements of the report end users.   The reporting solution must balance report generation speed, flexibility, and data availability.

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Using Microsoft SQL Express Edition to Log Data

For data logging and reporting applications it is optimal to have plenty of processing power, disk space, and memory.   Our typical database solution is to use Microsoft SQL Server Standard Edition on a Windows Server operating system, on a well provisioned Virtual Machine.  

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Understanding SQL Server Database Backups and Recovery Models-2

Understanding SQL Server Database Backups and Recovery Models

How to avoid some of the SQL Server database issues related to database files and backups in control system application databases and data logging databases.

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Creating Totalizers in PI Server Historian

Calculating totals is common in control system and facility monitoring applications. Frequently this is accomplished using totalizers in devices such as PLCs or meters. Device totalizers are useful but can be difficult to incorporate into reporting since they may have unexpected resets.

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Creating Totalizers in PI Server Historian

How to create email notifications

How to Create Email Notifications Using OSIsoft PI Data Server, Rockwell Data Historian, and Microsoft SQL Server

If your control system software does not support email notifications and you would like notifications for alarms, events, and process excursions,  here are two ideas for email notifications that can be implemented with commonly used database software.

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Introduction and Optimization of Data Historians

A Data Historian is a type of time-series database designed to efficiently collect and store process data from a SCADA or automation system. The stored data can then be used to display trends of process data on charts, create reports, or perform data analysis.

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case sudy data reporting university

Case Study: A Data System for Reporting, Trending and Analysis

A university in New England has a large campus with many buildings, research facilities, and activity centers. The university facilities group needed a data system to aggregate utility and HVAC data from multiple control systems into a common time-series historian database for data reporting, trending, and data analytics. The OSIsoft PI System was chosen. 

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Free Your Spreadsheet Data

Using a spreadsheet allows to easily capture the data, organize it by columns and rows, sort it by one or more columns and format it for easy viewing.  However, as the complexity of the data increases and as more and more users need to access this data, the utility of using a spreadsheet becomes questionable.

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When a Screwdriver Just Won’t Do… Building Custom Software Tools for the Job

Any task that includes the management of large amounts of data, repetitive entries or utilizes the same information in multiple places lends itself to developing software that can automate these activities.  The benefits from a well designed and implemented application can include greatly improved productivity and quality.  

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Case Study: Bringing Preventative Maintenance from Excel to a Modern Application

A client in the food and beverage industry located in Vermont has been using paper to track maintenance operations. Every week, the maintenance operators would write down the maintenance operation that needed to be performed for each piece of equipment on a large piece of paper.

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case study mineral process - document migration

Case Study: System Documentation Migration from Legacy to Modern

The automation team asked Hallam-ICS to develop a modern Web Application to save the data into an SQL Database, keep it compatible with the existing SCADA application and add new features to it. The new application allowed the creation of rack and card templates to simplify the data entry and reduce the mistakes.

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Case Study: Migrating from Excel to Modern Applications

Hallam-ICS built a database driven web application that would allow users to enter data which was governed by business and database rules. In addition, the report that was manually created in a spreadsheet was now automatically generated which increased accuracy and efficiency.

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case study globalfoundries tgms manufacturing intelligence


Using Real-Time Tables for Manufacturing Intelligence Reporting-1

Using Real-Time Tables for Manufacturing Intelligence Reporting

An a manufacturing environment, there is frequently a need to report on very recent production data in a dashboard that displays “real-time” data. The data for the current day or previous day generally is the most frequently used and queried data. 

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Faster Batch Reports from Multiple Data Sources

No one wants to wait minutes for a control system batch report to run. When reports need to run fast, design choices must be used that focus on the needs of the end user and consumers of the data. The standard for report design is to base the report data on “a single version of the truth”. 

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Excel Is Still Relevant For Reports And Data Analysis

There are many modern data visualization and data analytics tools used for manufacturing intelligence (MI).  Some, such as Microsoft’s PowerBI, have advanced data visualization capabilities that make products such as Excel seem rather dated; yet, Excel continues to be widely used. To understand why, let’s look at some examples.

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What's new in SQL Server Reporting Services?

SQL Server Reporting Services (SSRS) is part of the Microsoft Business Intelligence solution. Microsoft has been a leader in the Gartner Magic Quadrant for Business Intelligence and Analytics Platforms for the past 8 years.

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'Visible Data' – Seeing is Believing

At Hallam-ICS we have deployed many virtualized Process Control Systems (PCS). These systems are scalable from a large enterprise system to a small manufacturing facility. It is interesting to see the level of interest from operations, maintenance and management staff as they are introduced to the ‘Visible Data’.

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Equipment Energy Usage – My Favorite MI Project

Our client needed a solution to collect and visualize energy usage data on equipment at multiple manufacturing sites.  The objective was to get a better understanding of where energy is used, the associated costs, and gain insights into saving energy and money in the manufacturing process.  In this case the energy mix was in the form of electricity, nitrogen, compressed air, and natural gas.

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case study Smithfield bacon Ignition Scada

Case Study: Ignition SCADA Programming

Smithfield asked Hallam-ICS to configure a SCADA system using Ignition to display real time Overall Equipment Effectiveness (OEE) information for the
manufacturing floor and to provide regular reports showing production results for each shift.

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Case Study: Overall Equipment Effectiveness System

The engineering team and operations staff were looking for reports, key performance indicators (KPIs) and dashboards that would assist them in their efforts to reduce machine downtime. The engineering team was also looking for a standardized and well documented solution that could be rolled out across multiple sites in a timely manner.

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case study OEE Food Bev Conf Client

case study product line run rates

Case Study: Data Analytics to Obtain Production Line Run Rates for Scheduling

It was important that the data analysis results be traceable back to the originating data, so that the calculated results could easily be verified and trusted.  It was critical that the report run fast and be available to users with newly processed results for all production lines.

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