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Manufacturing Centralized Control System (CCS)

The Manufacturing Centralized Control System (CCS) is an advanced control system developed to meet the core demands of modern manufacturing, such as retrofitting legacy equipment, coordinating production processes, and unlocking data value. This solution aims to achieve high integration and coordinated automated management of production equipment through modern technologies like PLC control, Industrial Ethernet, OPC UA communication standards, and SCADA platforms. The solution integrates core functions including remote centralized control of equipment, safety interlocking for key processes, real-time data acquisition and visualization, and seamless integration with the upper-level Manufacturing Execution System (MES). It is dedicated to helping manufacturing enterprises break down information silos, improve production efficiency, strengthen safety guarantees, and lay a solid foundation for comprehensive digital transformation.

Industry Pain Points

Industry pain points

In their digital transformation, manufacturing industries commonly face challenges such as aging equipment, information silos, and safety risks.

Decentralized Equipment Control

A large number of devices operate independently, lacking a unified monitoring platform, resulting in low operational efficiency and difficulty in coordinated work.

Lack of Interlock Control

Absence of reliable automatic interlock protection between key processes, posing safety hazards and quality risks.

Severe Data Silos

Production data cannot be effectively collected and utilized, hindering production optimization and refined management.

Difficulty Integrating Legacy Equipment

Existing old equipment has diverse interfaces and inconsistent protocols, making upgrades, retrofitting, and data integration extremely difficult.

Solution Objectives

Achieve Centralized Management & Control

Establish a unified operation and monitoring center to achieve remote centralized control and status monitoring of all plant equipment, improving response speed and collaborative efficiency.

Strengthen Safety Interlocking

Build a reliable and efficient automated safety interlock protection system to eliminate key safety hazards in the production process, ensuring personnel and equipment safety.

Break Through Data Links

Enable vertical data integration from the equipment layer to the management layer, eliminating information silos and providing a foundation for data-driven decisions and intelligent applications.

Lay the Cornerstone for Transformation

Create an open and scalable automation platform, paving the way for the enterprise's future deployment of more advanced smart manufacturing applications like MES and Digital Twins.

Product Architecture

We adopt a layered, modular design philosophy to build a stable, reliable, and easily scalable centralized control platform.

Field Device & Control Layer

Deploy modern PLCs and distributed I/O, connecting sensors and actuators via high-speed buses like PROFINET/EtherNet-IP to achieve precise equipment control.

Monitoring & Operation Layer

Achieve plant-wide equipment visualization, centralized monitoring, alarm management, and remote operation through a redundant SCADA system.

Production Operations Layer

Seamlessly integrate with the MES system via OPC UA to enable production scheduling, quality traceability, and Overall Equipment Effectiveness (OEE) analysis.

Enterprise Management Layer

Upload key production data to ERP or cloud platforms to provide data support for enterprise decision-making.

Solution Highlights

Highlights of the plan

The core advantages of our solution are designed to provide you with exceptional value and experience.

High Reliability & Safety

Utilizes industrial-grade redundant design and independent SIS components to ensure 7x24 stable system operation, safeguarding critical processes.

Excellent Openness & Compatibility

Based on international standards like OPC UA, easily integrating new and old equipment, breaking down brand and protocol barriers, and protecting existing investments.

Modular Design & Phased Implementation

Provides a flexible modernization path, supporting phased and zonal implementation to minimize impact on production.

Future-Oriented Scalability

The platform-based architecture reserves interfaces for integrating advanced applications such as predictive maintenance, AI analysis, and digital twins.

Core Functions & Advanced Features

Core functions

The platform offers comprehensive control and management functions with powerful scalability, continuously creating value.

Visualized Centralized Monitoring

Provides customized process flow diagrams, trend curves, and reports to grasp real-time equipment status and the overall production picture, enabling strategic oversight.

Remote Control & Interlocking

Enables remote start/stop and parameter adjustment of equipment, while embedding reliable interlock logic in the PLC to ensure safe and orderly production.

Integrated Alarm Management

Centralizes the management, categorization, filtering, and logging of all alarm events, pushing critical alarms via SMS or App to ensure rapid response.

Performance Monitoring Dashboard

Displays real-time KPIs such as OEE, output, and energy consumption, helping managers quickly gain insights into production status and make informed decisions.

Predictive Maintenance (PdM)

Analyzes equipment data using AI to predict failures in advance, reducing unplanned downtime and shifting from 'reactive repair' to 'proactive maintenance'.

Deep Integration with MES/ERP

Connects the information flow from planning to execution, enabling automatic dispatch of production orders and real-time upload of production data to build a transparent factory.

Solution Value & Expected Benefits

benefits of the plan

Our solution is committed to delivering quantifiable, multi-dimensional value enhancement to your business operations.

30%

Improved Operational Efficiency

Significantly increases production efficiency and equipment utilization through automation and process optimization.

99.9%

Safety & Compliance Assurance

Reliable remote interlock control minimizes safety accidents and ensures compliance with industry safety regulations.

50%

ReducedDowntime Costs

Drastically reduces unexpected downtime and high maintenance costs through predictive maintenance.

Empowering Continuous Innovation

The open platform architecture provides a solid foundation for the company's digital transformation and continuous process innovation.

Application Case

Application cases

A Precision Equipment Manufacturing Enterprise

Witness how CCS helped a client achieve a leap in productivity.

Customer Background & Challenges

The client is a leading domestic manufacturer of precision equipment. Their assembly workshop had multiple machining centers, heat treatment furnaces, and cleaning equipment from different eras and brands. Production was highly dependent on manual scheduling, equipment status was opaque, and the critical heat treatment process lacked automatic interlocking with preceding and succeeding processes, which had led to batch scrappage incidents due to operational errors.