Plant Digital Integration — Multi-OEM SCADA & Cloud Reporting

Overview

Our client operates multiple concrete sleeper and track component manufacturing plants equipped with diverse OEM machinery — each with its own PLC and control system. As part of Indian Railways' quality and modernisation initiative, Railways required complete plant quality data to be visible to them on a real-time basis.

Elezon designed and deployed a complete plant digital integration solution — connecting multi-OEM PLCs across all process equipment into a unified AVEVA Plant SCADA platform, building a custom Influx database and dashboarding layer, and establishing real-time MQTT data transfer to the cloud.

Client challenges

The customer several data and integration issues:

• Multi-brand OEM equipment — each machine with its own PLC, protocol and data format — no single integration layer

• Indian Railways requirement: complete plant quality data visible in real-time via cloud

• Process stages involving not just PLC data but also PDF documents and manual operator entries at various stages

• Complete audit trail required — every production event, quality check and process stage must be traceable

• No existing reporting or dashboarding — plant had zero visibility into consolidated production analytics

• Data transfer to cloud required to be secure, real-time and protocol-compliant

• Manual data collection and inconsistent reporting

Objectives

The primary objectives of the project were to:

• Integrate data from all multi-OEM PLCs across plant equipment into a single platform

• Build unified AVEVA Plant SCADA for plant control, monitoring and quality supervision

• Enable data ingestion from PDFs, manual operator entries and automated PLC feeds

• Create complete audit trail covering all process stages and quality events

• Deploy Influx database for high-frequency time-series data storage

• Build customised advanced reporting and dashboarding for plant management

• Establish real-time MQTT data transfer to cloud — Railways quality visibilityEnable real-time monitoring of production and operations

Solution approach

Elezon designed a layered digital integration architecture — with multi-protocol PLC connectivity at the field layer, AVEVA Plant SCADA as the plant supervision layer, Influx database as the time-series data layer, and a custom dashboarding and reporting engine above it.

Data ingestion was built to handle three source types simultaneously: automated PLC feeds from multi-OEM equipment, extraction from PDF quality documents, and manual operator entry at key process stages. Every data point enters the audit trail — creating a complete, traceable record of every production event.

Real-time MQTT protocol transfer to cloud gives Indian Railways live visibility into plant quality data — meeting their modernisation and quality oversight requirement without any manual reporting effort from the plant.

Key components of the solution included:

• Multi-OEM PLC integration — custom drivers and protocol adapters for each equipment brand

• AVEVA Plant SCADA — unified plant control, monitoring and quality supervision

• PDF data extraction — automated ingestion of quality documents into the data platform

• Manual operator data entry interfaces — at key process stages

• Influx database deployed as container — high-frequency time-series data storage

• Custom advanced reporting and dashboarding — production analytics and quality KPIs

• Complete audit trail — every process event, quality entry and operator action logged and traceable

• Real-time MQTT protocol data transfer to cloud

• Secure data pipeline — plant to Railways cloud with protocol complianceStandardized data models and communication protocols

Implementation process

The project was executed through a structured and low-risk process:

• Discover & Integration Design
  Full plant audit of all OEM equipment. PLC protocols, data formats and communication interfaces mapped for each machine. Integration architecture designed for multi-source data ingestion.

• SCADA & Database Build
  AVEVA Plant SCADA configured for plant-wide monitoring. Influx database deployed as container. Custom dashboards and reports built for plant management and quality KPIs.

• Data Ingestion Layer
  Multi-OEM PLC connectors built and tested. PDF extraction engine deployed. Manual operator entry interfaces configured at all required process stages.

• RITES Cloud Integration
  MQTT data transfer pipeline established. Real-time data flow tested and validated with RITES. Audit trail verified end to end.

• Go Live & Handover
  System commissioned with live data from all sources. Plant team trained on SCADA, dashboards and data entry interfaces. RITES cloud data visibility confirmed and signed off.

Conclusion

Elezon delivered a complete plant digital integration solution for a multi-OEM manufacturing environment — unifying data from diverse equipment brands, manual process stages and quality documents into a single platform, and transferring it to Indian Railways cloud in real time.

The solution gave the plant its first consolidated view of production and quality data — and gave Indian Railways the real-time plant visibility their modernisation programme requires. Complete audit trail, zero manual reporting to Railways, and a scalable platform that can extend to additional plants without re-architecture.