A Smart PLC and SCADA based control framework for automated assembly line in process industry with effluent ratio control strategy.

Supervisory control and data acquisition (SCADA) systems play a crucial role in monitoring the behavior of critical process variables and integrating geographically dispersed subsystems within industrial plants. The majority of critical infrastructure networks like the production of electricity, mining deposits, natural gas, oil pipelines, heating systems and chemical product distribution use SCADA for monitoring, control and supervision. This paper presents a Programmable logic controller (PLC) and SCADA-based control framework to automate the process industry plant and monitor all the processes using a single-screen human-machine interface (HMI). This paper aims to address a dynamic real-world problem for the mixing of raw materials, filling of final product composition, capping, labeling and sorting of containers based on both size and type (metallic and non-metallic) using a single assembly line. In this context, a ratio control framework is proposed for adjusting the ratio and mixing of raw materials. The OMRON (NX1P2-9024DT1) PLC controls the entire process, with its programming carried out using the ladder programming language in Sysmac Studio automation software. Wonderware Intouch SCADA software is used to visualize the two stages independently. A mathematical and simulation model is proposed to minimize the assembly line timings, the workforce and overall cost of production. The developed model is applied in a real-life case study of an assembly line from a chemical process industry supplier in northern India. In addition, the results of a real-world case study verify the design for effectively balancing a real-world assembly line and show that the proposed system improves the productivity, efficiency, throughput, workforce, cost and time of a process industry. [ABSTRACT FROM AUTHOR]