A manufacturing client needed an "end of the line" production pacing system so that the production crew could tell whether they were going to meet their shift production goals or not. This could show the team there were problems BEFORE they got too far behind to catch up.

The quotes the client received from their internal engineering team and their PLC automation companies priced the project out of reach.

The client asked if the Ferox team wanted a shot at it. We did

We created a hardware/software system using off-the-shelf hardware, open source software and our own custom software.

The system we created, called PACE, is a standalone system that doesn't rely on an ERP or production control system because it interfaces directly with the robotic workcell. The workcell reports good parts and bad parts by sending us 24 volts DC on two separate links.

PACE tracks the signals and records production data in an open source database. A small touchscreen HMI is used to enter new parts and, when not doing that, it displays the PACE status board. A separate TV monitor mounted above the production line lets management see from a distance what is happening (or not happening) on that production line for the current run.

The system projects completion time and shows progress. While the calculations themselves are not particularly complicated, the system takes into account a complex schedule of breaks, shift start and end times, defective part counts, and indicates progress with relevant numbers, percents, and colors.

Multiple machines are able to be easily consolidated into a central dashboard.

The system helps employees so they can self-manage to improve production. Management has better visibility and insight into key production indicators.

The system was delivered for 40% of the cost of a less flexible traditional automation solution. We could do that because we saw the problem as an off-the-shelf hardware/custom software solution instead of a PLC automation solution. The system was delivered on time and on budget. We easily duplicated it for other production lines.

Ferox got it done on time and on budget. When we added to our original concept, they were able to easily adapt and improve the system. This is EXACTLY what we needed.