Work
Selected work
MES, SCADA, integration, vision, and engineering-data work - described by industry and scope.
Client names are withheld by default. Ask if you need them.
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Enterprise Ignition MES and SCADA across multiple manufacturing sites
One enterprise MES and SCADA platform across multiple manufacturing sites - the architecture designed on a blank sheet, and the systems running today: track and trace, gate checks, database front-ends, and production reporting.
- MES, server, network, database, and application architecture designed from scratch, with Ignition Vision and Perspective applications for production, quality, traceability, reporting, mobile operations, and management dashboards
- Reusable templates, standard tag structures, and communication frameworks, so new lines and sites commission from a proven baseline
- Integrations between Ignition, ERP, label printing, battery test systems, SQL Server, Azure, and Kepware, including test-result capture against the right unit
- Remote engineering environment built to ITAR/NIST requirements
- Requirements worked out directly with production and quality teams, then turned into MES workflows and operator screens
Architecture and ownership
- Ignition Vision
- Ignition Perspective
- MES
- SCADA
- OPC-UA
- Microsoft SQL Server
- Azure
- Kepware
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Greenfield gigafactory: MES and SCADA specifications through startup
MES, controls, and IT/OT specifications written before equipment was ordered, then held against machine builders through commissioning and startup - and the Ignition Perspective standards the plant was built on.
- Enterprise MES and SCADA strategy for a greenfield plant, with specifications for machine builders and software vendors written before procurement
- Enterprise standards for PLC handshakes, track and trace, OEE, historian, APIs, and data collection
- Machine builder designs reviewed against the MES specification, then validated and enforced through FAT, commissioning, and startup
- Ignition Perspective patterns and standards carried across three plants in startup phase, with OPC-UA servers and Mitsubishi PLCs feeding plant-wide data collection
- Enterprise Ignition Perspective applications with Azure integrations
Specification, standards, and startup
- Ignition Perspective
- MES specifications
- PLC handshakes
- OPC-UA
- Mitsubishi PLCs
- OEE
- Historian
- Azure
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Ignition rollout and custom MES migration for a battery manufacturer
Led the MES program end to end: the plan to move off a custom MES onto Ignition, the development that followed, and the plant teams brought along with it.
- Project plan for the implementation and migration from the custom MES to Ignition
- Battery pack line MES developed with a machine-builder partner
- Consulting support for plant MES developments in Europe and China
- OEE and yield studies at the system and process level, plus custom web reports and tools
Program leadership
- Ignition
- MES migration
- OEE
- Oracle
- Microsoft SQL Server
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Automated visual inspection on a live production line
Photo eyes on a live production line triggered a Raspberry Pi to photograph each part, and a TensorFlow model classified it as good or bad.
- Result displayed in Ignition Perspective, and a bad part stopped the conveyor
- Operator confirm or override corrections fed back into retraining the classifier
Machine vision
- TensorFlow
- Raspberry Pi
- Computer vision
- Ignition Perspective
- Python
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Battery gigafactory SCADA
Ignition Perspective SCADA for a battery manufacturing gigafactory, from track and trace through MES administration.
- Track and trace and gate checking
- Recipe management
- MES admin dashboards and reporting
Client delivery
- Ignition Perspective
- Microsoft SQL Server
- Docker
- Git
- Raspberry Pi
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Plant overview with live AGV tracking - defense industry
A plant overview showing the status of every station plus the real-time position and status of dozens of AGVs.
- Pan-and-zoom container for the whole plant
- Abstracted into a reusable template for fast deployment
Client delivery
- Ignition Perspective
- FactoryTalk
- AGV tracking
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Warehouse management system in Ignition Perspective
Internal warehouse management system in Ignition Perspective, delivered with a small team.
- Warehouse material management and material transfer history
- Picklist submission
- User management and reporting
Application build
- Ignition Perspective
- PostgreSQL
- Git
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Robot vision guidance for 3D inspection
Vision guidance software for robot cells, taking a single 2D, 2.5D, or 3D camera and telling the robot where the part is.
- Vision algorithms developed and debugged in production software
- Imagery and lighting setups for vision-guided robot cells
- GUI work in Qt/C++ and embedded vision PCs built for the lab and for customers
Machine vision
- Computer vision
- Qt / C++
- Embedded vision
- ABB, Fanuc, Motoman, Kuka
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Emissions test system modernization - automotive
Modernizing corporate emissions test software and simulators, moving Fortran-era code onto a new database and a C++ codebase.
- Fortran 95 to C++ conversion for the modernization effort
- Database tables built and maintained to EPA test specifications
- Driving test schedules created for international emissions programs
Client delivery
- FORTRAN
- C++
- Microsoft Access
- HP1000
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Mass properties data systems for defense vehicles
Engineering data systems behind vehicle mass properties work on combat vehicle programs, with 3D model data pulled into relational databases.
- Custom databases holding vehicle information and mass properties statistics
- Data extracted from Pro/ENGINEER and UniGraphics models into Microsoft Access
- 3D models imported and analyzed across CAD and PLM tools
Engineering data
- Teamcenter
- Pro/ENGINEER
- UniGraphics
- Microsoft Access
- DBmass
Want the detail behind any of these?
We can walk through the architecture, the tags, and the parts that were hard.