Failure of industrial furnaces can lead to serious consequences - from financial losses due to downtime, to loss of batch quality, to disruption of the entire production chain. Lack of rapid access to process data further hinders the response to irregularities, which can escalate the problem and increase repair costs and production losses. In this case study, we will show how the implementation of a state-of-the-art SCADA system changed the way furnaces are managed at grinding tool manufacturer Lapport Schleiftechnik GmbH. Among other things, you will learn how the lack of remote access to data affected production efficiency, how SCADA integration allowed for faster response to breakdowns, and how the ability to analyse data in real time allowed for more informed production management. Read on and discover how modern automation solutions can improve production and reduce the risk of failure!
Industrial furnaces play a key role in advanced technological processes, such as the precision firing of grinding tools. It is their reliability and accurate control of parameters, such as temperature, that determine the quality of the final product. Even small deviations in settings can lead to serious problems - from loss of batch quality to costly downtime.
Traditional process management systems, based on manual operation or limited automation, involve the risk of human error and a lack of real-time transparency. Process data is often difficult to access and can take a long time to analyse, making rapid decision-making difficult.
A SCADA (Supervisory Control and Data Acquisition) system completely changes the way industrial furnaces are managed. It enables real-time monitoring, analysis and optimisation of processes, providing operators and production managers with all the necessary data in one place. With SCADA, every step of the process can be precisely controlled, the risk of failure can be minimised and production can be effectively managed. In modern industry, this solution is no longer a luxury but a necessity in order to meet the increasing quality and productivity demands of production.
Prior to implementing a SCADA system, Lapport Schleiftechnik GmbH was struggling with significant limitations in the process management of its industrial furnaces. The biggest problem was the lack of remote access to process data and limited ability to monitor parameters in real time. Operators had to rely on local readings and manual reporting, which did not allow them to react quickly to emerging problems and failures. Operators did not have the ability to monitor multiple furnaces simultaneously and the available data was scattered. Decision-making was based on fragmented information, increasing the risk of errors and inefficiencies.
Faced with these challenges, Lapport was looking for a solution that would provide remote access to data, simplify operation and enable rapid response to alarms. It was also important that the new system easily integrated with the existing automation infrastructure, based on the JUMO mTRON T PLC automation system.
Lapport Schleiftechnik GmbH gained completely new process management capabilities with the implementation of the JUMO smartWARE SCADA system, which was integrated into the existing JUMO mTRON T automation system via the Modbus TCP protocol. This integration allowed the two systems to be seamlessly linked, enabling full process data monitoring and alarm management from a single platform. A solution was developed for Lapport Schleiftechnik that displays and records analogue furnace measurement values in the form of curves.
The new system offers key functionalities that have significantly improved the operational control of industrial furnaces. Remote access to process data allows operators and production managers to monitor furnace performance in real time from anywhere using a web browser. To visualise the data, we developed a customised dashboard that shows setpoints, actual values, faults and alarms of the JUMO mTRON T PLC.
In addition, advanced alarm management allows the relevant persons to be automatically notified by e-mail or SMS when a fault occurs. Malfunctions and alarms are presented in the form of light signals, and all problems arising are archived in a special register. The light turns yellow in the event of a fault and red in the event of an alarm. All data is archived, allowing it to be analysed and process history to be reconstructed at any time.
The JUMO smartWARE SCADA software (701820) was integrated into the existing JUMO mTRON T PLC (705001) via Modbus protocol.
The implemented data visualisation system based on JUMO smartWARE SCADA has opened up new possibilities for production process management at Lapport Schleiftechnik GmbH. Real-time visualisation has made the operators' work much easier. Thanks to the clear presentation of parameters and traffic lights, staff can quickly identify abnormalities and respond to them immediately.
From a management perspective, the implemented system has also brought long-term benefits. The archiving and analysis of process data has enabled better planning of preventive measures, the elimination of human error and the optimisation of furnace operating parameters. As a result, the company was able not only to reduce the risk of downtime, but also to improve the quality of the grinding tools.
In addition, the SCADA software was designed as a scalable solution, meaning that Lapport can expand its use to other production lines or implement additional functions in the future. In turn, the process data history has become a valuable source of information for further optimisation and innovation of production processes.
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My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.
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