To begin designing a solution for the client, DMC met with key stakeholders to learn about the various departments and their functions. After understanding the client’s business model, DMC worked with each department head to determine what combination of Microsoft solutions was needed. This holistic approach allowed DMC to leverage Microsoft technology across departments and minimize information silos. 

Design and Development 

After gathering requirements, DMC began implementation. This included a custom SharePoint navigation header to easily navigate between site collections, creation of each site collection, and implementation of the SharePoint content managers such as document libraries, lists, pages, and news posts. 

DMC also created Power Automate workflows to minimize redundant tasks. For example, a Microsoft Form was created to allow external users to submit survey responses. When new responses were received, they were automatically added to a SharePoint list. This minimized the number of application touch points needed for day-to-day work. 

Additionally, DMC organized all the client’s SharePoint content into a spreadsheet to document permissions. DMC collaborated with the client’s IT department to create the necessary Active Directory and Microsoft 365 groups to efficiently manage permissions. 

Testing and Deployment 

DMC took an iterative approach to development, testing, and deployment. During the creation of features, the SharePoint site was locked down to those involved with development. Once larger features were implemented, the department heads were granted access to provide feedback. After all department heads were satisfied with their site and permissions were checked, the site was ready for the go live! 

Training and Support 

Prior to go live, DMC conducted both end user training and administrative training. During end user training, users received training on how to navigate the contents of the site and utilize other basic features such as adding files to a document library, adding and removing items from lists, and how to filter and sort lists to quickly find information. 

Administrative training was more in-depth and included tasks like updating list views and columns, updating pages, managing webparts, and managing permissions. 

Both training courses were vital in giving the client the confidence they needed to manage the site. Additionally, DMC continues to support the client by providing ongoing consultation on features and performing complex configuration as needed. 

Conclusion 

DMC’s detailed approach to implementing SharePoint sites gives clients a reliable framework to manage their business content. To learn more about how DMC can customize a Microsoft solution for your organization, contact us for your next project.

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DMC began by scheduling a site visit to transcribe the current Omron PLC program, generate an I/O list, take dimensions, and create a rough functional specification for the machine. DMC also investigated the programmed Omron functions, with the expectation that most built-in functions would not be a direct translation into the new program. 

We then specified what hardware would be best suited for the project based on the client’s needs, and we decided to use Siemens S7-1511 PLC due to the high hardware availability, low costs, and string feature set. We started on the translation of the complex Omron instruction list code to ladder logic, using TIA Portal as the programming software. 

Siemens S7-1500 PLC 

DMC successfully ramped up on the SYSMAC C-Series technology in a timely manner and utilized our expertise in the Siemens platform (including automation hardware, PLC programming, and onsite commissioning) to develop a robust solution that will be maintainable and supportable going forward. 

As we moved into the commissioning of the project, DMC’s hardware subcontractor wired and replaced the PLC. DMC then started the I/O checkout and commissioning. During the I/O checkout, we were unable to read any of the sensor inputs and soon realized that the old sensors were not compatible with the new PLC. The client needed the machine to be up and running within two days, so we provided an alternative, timely solution to replacing the sensors and added relays to switch the polarity of the sensor signal.

Learn more about DMC’s Legacy PLC Upgrade and Conversion Services and contact us today for your next project.

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Image of PCB

The project started by evaluating different motor control technologies from the leading motor control vendors in the industry. Controllers must be able to operate in both sensored and sensor-less modes, be easily reconfigured to drive different motors in different applications, and be tunable on the fly to properly match the needed application.

TI MotorWare technology proved to be a great fit for these requirements. DMC then developed software to expand and optimize the TI MotorWare project to address the client’s need for a near universal PMSM motor controller. 

DMC worked closely with the client to design the custom PCBs for the controller and power electronics. These PCBs had to fit in an extremely small envelope to be used with the client’s smallest devices while also having the efficiency and thermal dissipation to effectively drive the client’s more powerful motors. We achieved this with a highly integrated design between the housing and PCB. With this, we used the latest Intelligent power modules from Infineon that allowed for high peak and sustained currents in a very compact design by integrating a half bridge and mosfet drivers into a single IC.

Learn more about DMC’s Embedded Development and Embedded Programming expertise and contact us today for your next project.

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As a potentially life-saving device, it is extremely important that every AED is checked regularly for proper functionality. Previously, most of this monitoring process was manual — an employee went around to each AED cabinet to physically check if each device was working correctly. This posed a few problems. First, if an AED were not functioning, it would only be discovered and resolved once an employee manually checked the device. Physically checking each AED cabinet can be very time-costly and is subject to human error.

DMC helped integrate an IoT solution so the monitoring could be performed remotely to mitigate these safety and inefficiency issues. Now, each AED is mounted inside of a cabinet fitted with an RMS connected to a cellular network. All AEDs perform self-checks on a regular basis. Using patented technology, the RMS can now sense the electrical activity within the AED during its self-checks and determine if the AED is operating correctly. If no electrical activity is sensed, or the AED fails its self-check, the RMS will send a notification via cellular network so that action can be taken to promptly replace the failed AED. 

By changing the AED monitoring process from manual to an automated remote monitoring system, the client’s RMS drastically reduced labor and maintenance costs, mitigated human error, and allowed for real-time monitoring of AEDs. With up to a ten-year battery life, the new device is now as dependable as it is effective. DMC is proud to have worked with this client to develop a product that has the potential to save many lives. 

Read more about DMC’s Embedded Development and Embedded Programming, and contact us to get started on your next project. 

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WinCC OA SCADA Configuration and Integration

DMC utilized WinCC OA to provide a centralized interface for plant control and monitoring. DMC utilized Redundancy in WinCC OA to meet the high availability requirements of the plant. A custom user interface was developed utilizing high efficiency HMI design principles. This system provided key features such as data acquisition and archiving to Oracle database, alarm monitoring and SMS/email notification, and audit trail functionality for regulatory compliance (21 CFR Part 11).

Electrical Design and Build

DMC worked with partners to design and build electrical panels for a variety of systems. The panels met the client’s requirements including NEMA, UL, and safety requirements. As a close Siemens partner, DMC worked with Siemens application engineers to select the hardware necessary to meet the client’s needs.

PLC Programming

DMC designed and implemented PLC programs for the facility’s manufacturing utilities and monitoring systems. Successful integration required close coordination between DMC and our client’s process and controls engineers.

OEM Equipment Integration

DMC integrated dozens of OEM vendor systems into WinCC OA for data acquisition and monitoring. We reviewed vendor code and integrated a variety of systems utilizing WinCC OA’s extensive communication drivers to communicate with many different platforms (Siemens, Rockwell, GE iFix, Wonderware/AVEVA, etc.).

Documentation and Regulatory Compliance

Throughout the project, DMC followed Good Manufacturing Practice (GMP) guidelines to ensure quality standards and meet regulatory guidelines. We generated software and hardware test plans during the development cycle, wrote qualification documents for installation and operation qualification, and provided onsite support for equipment commissioning and qualification.

Learn more about DMC’s WinCC Open Architecture Development expertise and contact us today for your next project.

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Our engineers commissioned the skid and wrote batch reports on a machine set up with Siemens WinCC 7. We reorganized some of the client’s screens and tracked logging in to ensure permissions were secure. With traceability of high importance, DMC took all the key process information and recorded them. This included any types of alarms or deviations occurring during the process. At the end of a run, DMC printed out the batch report using built-in WinCC reporting our engineers wrote while on site.

DMC got the skid up and running after altering the testing process to monitor the flow rate of the system as opposed to looking at its pumps as they were fouling. With our automation expertise, experimentation, and refinement, we stabilized the pumps needed to run the machine.

We reviewed all of the validation documentation, assisted in the execution of it, and accounted for any deviation. While onsite, our engineers worked on the machine in clean rooms. The project involved lots of mixing, and there were tight ratios we had to work with. With our process control experience, we successfully monitored the mix between the multiple different types of fluids.

After our work on the first machine and ramping up on the process, the client asked us to act as their process experts on the commissioning of a second machine at another location.

Our expertise in Siemens HMIs and WinCC 7 and our overall Automation experience led us to successfully commission both projects.

Learn more about DMC’s Process Automation, and contact us today for your next project.

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For the customer to accurately monitor the state of charge remotely, DMC integrated a fuel gauge into the device, transmitted its status via Bluetooth, and created a manufacturing process to commission each unit during assembly.  DMC wrote a custom I2C driver for a TI fuel gauge sensor utilizing Texas Instruments Impedance Track (TM) Based Fuel Gauging. To accurately determine the battery status, a series of tests were performed to profile the battery pack and determine the battery chemistry. This battery chemistry ID was used by the fuel gauge to accurately determine the state of charge of the battery pack compensating for self-discharging as well as battery aging. During manufacturing, each fuel gauge was programmed and calibrated using TI’s Battery Management Studio (bqStudio).

DMC helped the customer solidify their hardware design for manufacturability and consistency. DMC used reverse engineering to recover their existing design files.  DMC applied our best practices for printed circuit board (PCB) design to improve the client’s latest revision of the device; so, it could be utilized in their research. This additionally included updating and modifying the Python-based PC application to support plotting and report generation to be able to properly evaluate the performance of the prototype system.

In the end, we leveraged our extensive hardware design experience and vast embedded software experience to pick up existing designs and to build upon them — yielding a testable device for our client that is efficient and functional.

Learn more about DMC’s product development expertise and contact us to get started on your next project!

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The client’s set of two of Original Equipment Manufacturer (OEM) machines utilized different code bases but worked together to create oral tablets in batches. One machine mixed the dry ingredients to create a homogenous powder and the second machine then pressed this powder into tablets. Each machine was controlled by a Programmable Logic Controller (PLC) and ran separately with different recipes and configurations.

DMC Solution: Continuous Mixing and Pressing

DMC utilized the WinCC OA Supervisory Control and Data Acquisition (SCADA) system to help the client transition from this manual batch process to a more automatic continuous process. The WinCC OA program gives users an overarching view of the system and sends command signals and recipe configurations to and from both PLCs to control both machines as a unified system. This allows users to configure and control the entire process from a single interface rather than from two separate HMIs.

Centralized Recipe Management

In addition to centralized control, DMC utilized WinCC OA’s flexible database system and scripting to create and implement a centralized recipe system. Instead of recipes being configured and maintained separately on the OEM PLCs, users now can create, modify, and manage recipes for the system via a single interface. Selected recipe parameters are sent to the individual PLCs where they are implemented and run with the OEM code.

Our proficiency and expertise with WinCC OA led DMC to successfully convert the client’s batch processing system with separate machine controls into a continuous process with sequencing and recipe management controlled from a single interface.

Learn more about other HMI & SCADA solutions DMC has delivered to clients and contact us to get started on your next project.

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We made sure to program our automation system with an expandable and modular framework in mind. Therefore, the system can be easily modified in the future to flexibly accommodate other processes with less engineering impact—making this a facility that can grow with our client. 

Overview

This large-scale project can be divided into three main components. First, DMC used our application development expertise to write multiple drivers. These drivers were responsible for integrating our customized automation system with their existing pieces of various nonstandard lab equipment. Next, DMC designed a custom Ignition SCADA system, which served as the user interface (UI) for the entire laboratory and the database infrastructure (mainly for CLIA compliance). Lastly, DMC developed and built the automation system itself, which will be the focus of this case study.

Since the facility is so massive and the testing process is very complex, the testing line needed to be as flexible as possible. Therefore, the line was divided into work cells in which a small step of the process was performed in each. To return a test result, each sample needed to pass through every cell.

Transport System

These work cells were spread throughout the facility and connecting them was a MagneMotion transport system with three work groups. The samples travelled along this system to each work cell. DMC then designed Control GuardLogix PLCs to act as Line PLCs for the transport system—i.e., responsible for routing the samples and keeping track of where they are in the testing process. We also utilized Rockwell’s independent cart technology in this system to provide a standard architecture for how samples are routed throughout the facility. With thousands of sensitive biological samples traveling about a mile from start to finish during the testing process, it was critical that we had a system robust and reliable enough to handle so much data.

Due to the nature of certain lab operations, the system was separated between two laboratory rooms. DMC connected the rooms through an automated MagneMotion elevator to convey movers from one area to the other. The custom-designed elevator featured independent, synchronous Allen Bradley servos to seamlessly connect different levels of MagneMotion track.  

In addition, DMC programmed Compact GuardLogix PLCs for each work cell to control its equipment and properly execute its testing step. All fifty line PLCs and three cell PLCs used PackML architecture, which standardized information between work cells to ensure all machines were functioning in sync with each other.

In total, this massive project included thousands of motors, hundreds of paths, hundreds of nodes, and over ten node controllers. With our MagneMotion experience and wide variety of expertise, DMC was able to provide Ginkgo with comprehensive PLC, SCADA, and application development solutions to process over 100,000 samples a day. DMC is proud to have been part of Ginkgo’s effort to expand COVID testing and help develop a sequencing facility that can be used in many different ways for years to come. 

Learn more about DMC’s manufacturing automation expertise and contact us today to get started on your next project.  

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DMC’s team of expert HMI & SCADA engineers customized an Ignition system for our client that gathered data from seven machines. Each machine ran Ignition Edge and communicated its local machine data up to the main Ignition gateway. This allowed the system to automatically store and forward critical audit data and alarm information. In the event of a network failure, each machine could run on local machine control as well—making this system incredibly reliable.

Once the data was collected, various KPI analyses were automatically run. We developed a reusable library for calculating these key metrics, which allowed us to utilize the same script at both the machine and line level. This greatly cut down development and commissioning time, providing our client with a cost-effective solution.

In total, the Ignition system calculated twenty-six different metrics for each machine and the entire line, including OEE (overall equipment effectiveness) calculations. DMC developed a scheduler object for the line that allowed users to utilize these KPIs in tandem with scheduling operator shifts. For example, the user could schedule individual or recurring events, which Ignition would then use to automatically calculate key metrics for each shift.

Our customized system handled communication to the seven machines, as well as a remote recipe system. Therefore, DMC employed the Ignition sequential function chart feature to develop a state machine that ensured the remote system and the seven local machines were always operating synchronously with each other. In addition, we developed a material tracking system that logged all scanned materials in the line and would accept or reject them based on different criteria.

DMC’s solution not only increased the reliability and efficiency of the manufacturing line but also automatically gathered and analyzed key metric data. With the wide scope of recorded KPIs, DMC was able to provide our client with detailed reports of their machines. The client can use these reports to gain better insight into their production and make informed decisions to ensure a sustainable, profitable future.

Learn how DMC has helped upgrade other companies’ manufacturing lines and contact us today to get started on your next project.

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