Ignition’s Perspective – the perfect tool to use inside plants

The complexion of plant automation is evolving and clients realize that the term “automation” means much more than physical processes.  Users are increasingly seeking out applications that do more and are engaging to their personnel.  At PDA we’ve found Ignition’s Perspective platform to be the perfect tool to use inside plants for projects of all types.

A client recently contracted PDA to develop an Electronic Quality System (EQS).  This client envisioned a software solution to facilitate all manner of production quality tests, ostensibly replacing many manual testing and record keeping incidents within their plant.  They piloted “off the shelf” solutions in early attempts but found their operations to be too complicated to change to a rigid solution. They had multiple existing Ignition Vision solutions in plant along with a long working relationship with our team at PDA so they decided a custom solution might be the answer. PDA’s project approach of Discovery & Goal Setting followed by functional design specification (FDS), system pilot, revise FDS, then full system deployment was familiar to them, so they began with optimism.

Operators perform quality checks at multiple points in their process which makes Mexican entrees. The system needed to handle pre-production, during-production, and finished goods checks, most of which were manual examinations. The client preferred iPad tablets on the factory floor but the dynamic screen capabilities of Perspective were used to leverage many options. “This client had serious ideas about aesthetics and usability that they wanted to wrap into the system,” says Dan Garrity, PDA Sales.

Adding the Perspective platform within the plant was simple. Rather than increasing their server infrastructure, the system was added to an existing Ignition server, and it utilized existing tools and connections like the Active Directory link which existed for the Vision applications. This simplified development and makes maintenance of the applications easier.

We ultimately developed two solutions for them, a front side user-side interface and a second, back side element that allows the client to develop future test operations in-house.  The frontside application steps users through the required quality checks in multiple, selectable languages.  Plain language combined with pictures allows their team to see exactly what needs done and which information needs to be recorded.  We utilized Perspective’s simple language switching capabilities to accommodate both English and Spanish speaking personnel.  The backside application was huge for them as it would enable them to construct future quality tests without the need for outside assistance.

There are significant differences between developing in Perspective versus legacy SCADA solutions.  For developers this isn’t necessarily a bad thing as team members with a background in modern web development will find the tools intuitive and easy to implement. Ignition provides a suite of tools that aid in this development, thus helping tradition SCADA developers to adapt to the platform. Applications like this EQS could have been developed in a web platform with a language like C Sharp, however; we consider many things when determining the best path forward.  Building these tools in Perspective in this instance laid the groundwork to easily connect their in-plant industrial devices like scales and scanners so this was the best path for them.

The phased implementation is ongoing for this client.  Perspective will allow us to connect their HR system for expanded user and role management for tasks.  We’ll connect to the existing MES system to pull orders.  All the while, the sleek and functional interfaces will provide a dynamic platform that the operators like to use.  This client’s optimism has been rewarded and they have the beginnings of a large-scale solution that will eventually be rolled out to the balance of their facilities.