Context
Problem framing
CoreLink Automation operated semi-automated lines with limited visibility into bottlenecks and manual shift coordination. PLCs held the safety interlocks; any bridge could not compromise stop conditions or override logic.
Automation Systems · 2023
CoreLink Automation
PLC-integrated process automation with operations dashboard
Connected shop-floor PLCs to a unified control and analytics layer, optimizing production workflows end to end.
Challenge
Constraints
Integrate Modbus-speaking PLCs to a modern dashboard without production stops. Analytics had to reflect real cycle times, not optimistic estimates from shift logs.
Architecture
System design
PLC bridge service normalizing register maps, Node.js event bus fan-out, React operations dashboard with line-level drill-down, and alert routing to shift supervisors. Safety interlocks remain PLC-resident; software never bypasses hardware stops.
Delivery
How we shipped
Eight lines integrated in phased waves with operator sign-off each wave. Cycle time improved 19%; downtime alerts reached control rooms in real time. CoreLink maintenance staff inherited register maps and tuning guides.
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