In this project, we developed a custom solution using Ignition SCADA to enhance machine security, improve performance monitoring accuracy, and streamline operator scheduling. The system integrates with RFID readers that operators already use for building access. By leveraging the same RFID cards, operators are granted permission to access the HMI (Human Machine Interface) for machine operation.

The system records operator log-ins, timestamps, and activity, which are utilized for tracking both machine performance and individual operator efficiency. With this data, the calculation of machine downtime is now more accurate, as operator interaction times are precisely logged. Additionally, once the RFID card is removed from the reader, the system automatically logs out the operator and disables machine operation, ensuring secure processes and preventing unauthorized access.

A scheduling tool was also developed, using the recorded log-in data to visually display which operators were assigned or logged into machines at specific times on a calendar. This tool makes it easy to track operator schedules, ensuring efficient resource management and allowing supervisors to monitor operator activities in real-time.

This solution enhances operational efficiency, offers valuable insights into machine performance, and simplifies operator scheduling.

Case Study: Integration of Ignition Perspective with RFID READER for Machine access, Automatic Operator Schedule Management and Operator and Machine Performance Tracking

Introduction

In the fast-paced environment of modern manufacturing, effective workforce management is crucial for optimizing productivity and ensuring operational efficiency. This case study details the integration of Ignition Perspective with the RFID reader to automate operator shift scheduling and performance tracking. By leveraging RFID technology and Ignition’s powerful scripting capabilities, the solution significantly reduced manual scheduling efforts and improved accuracy in tracking operator attendance.

Objectives

• Automate Shift Scheduling: Eliminate the need for daily manual scheduling of operator shifts across multiple work cells.
• Improve Performance Tracking: Utilize RFID scans to accurately track operator attendance in real time. Tracking actual downtime for accurate performance tracking.
• Enhance Data Management: Store scan data in a centralized database for easy access and reporting.

System Architecture

The integrated system comprises the following components:

1. RFID Reader: Used for reading RFID tags assigned to operators.
2. Python Module: Developed to interface with the RFID reader, read RFID tags, and store the scan data in a database.
3. Ignition Perspective: Utilized for creating a user-friendly interface, including a calendar module for visualizing schedules and attendance.
4. Database: A centralized repository for storing scan data, operator information, and generated schedules.

Implementation Steps

1. Development of the Python Module

A custom Python module was developed to read RFID tags from the reader. The module included:

• Reading RFID Data: The module continuously monitors the RFID reader and captures scan events, recording the operator’s ID and the time of the scan (scan-in and scan-out).
• Database Interaction: Upon reading a scan, the module processes the data and inserts it into a pre-defined database table designed to store operator attendance logs.

2. Scripting in Ignition

Using Ignition’s scripting capabilities, a script was created to automate the scheduling process based on the scan data stored in the database. The key features of this script included:

• Data Retrieval: The script queried the database to fetch the latest scan-in and scan-out times for each operator.
• Schedule Generation: Based on the retrieved data, the script generated a schedule reflecting the operators’ shifts.

3. Displaying the Schedule in Ignition Perspective

The generated schedule was displayed in the Ignition Perspective calendar module, allowing operators and supervisors to view shifts in real time. The calendar interface included:

• Visual Representation of Shifts: Color-coded entries for each operator, making it easy to see who is scheduled at any given time.
• Real-Time Updates: The calendar automatically refreshed to reflect changes in attendance and scheduling as scans were recorded.

Results

The integration of Ignition Perspective with the RFID reader yielded significant improvements:

• Time Savings: Reduced manual scheduling efforts by automating shift generation, allowing supervisors to focus on other tasks.
• Accuracy and Reliability: Increased accuracy in tracking attendance and managing shifts, reducing the risk of human error.
• Enhanced Visibility: Provided real-time insights into operator attendance and scheduling through the Ignition calendar module.

Conclusion

This case study illustrates the successful integration of Ignition Perspective with RFID technology to automate operator scheduling and performance tracking in a manufacturing environment. The developed solution not only streamlined the scheduling process but also enhanced data management and attendance tracking. As a result, the plant experienced improved operational efficiency and better utilization of workforce resources. Future developments may include expanding the system to incorporate additional features such as alerts for shift changes and integration with payroll systems.