Why is precise temperature control crucial in industrial furnaces? Customer challenge

In grinding tool manufacturing, where quality and precision are an absolute priority, accurate temperature monitoring in industrial furnaces is a must. Even minimal deviations from established standards can lead to material defects or the need for re-manufacturing, which significantly affects production costs and efficiency. Lapport Schleiftechnik, as specialists in the production of these tools, are well aware of this. As a result, they have begun to modernize their processes - some time ago they sourced JUMO mTRON PLCs, and now they have approached us with a need for a system for value visualization and monitoring of tool firing processes and alarming.

The lack of such a system not only increased the response time to alarms, but also made it difficult to manage the process. In the event of a malfunction or sudden temperature rise, every minute without appropriate intervention meant production downtime, and thus financial losses. In response to these challenges, Lapport began looking for a solution that would not only improve temperature monitoring, but also contribute to the digitization and automation of the production process. In addition, they needed a system that would allow them to collect and analyze historical data, based on which they could optimize production and successively reduce the risk of operational errors and failures.

How has SCADA increased the precision of temperature control in industrial furnaces? Our solution

In response to the needs of Lapport Schleiftechnik, we developed a solution, based on our JUMO smartWARE SCADA system, which includes advanced monitoring, alarming and process visualization functions, allowing full control of industrial furnaces.

The SCADA program has been configured to interface with existing JUMO mTRON T control systems. Communication between them is via Modbus TCP protocol, allowing process values, such as temperature, to be read from measuring devices in real time, and then immediately processed and displayed on a customized dashboard. The interface presents the setpoints and actual values of the process parameters live in the form of graphs, allowing engineers to monitor changes and quickly detect deviations.

Lapport's SCADA system not only monitors, but also automatically alerts on any abnormalities. Intelligent alarming functions record deviations from the norm and send notifications to operators, depending on the alarm category set, via e-mail, SMS and even telephone, reducing response times. In addition, faults and alarms are color-coded on the dashboard (including yellow for warnings and red for critical situations), allowing priorities to be identified at a glance.

Process data archiving is an integral part of the JUMO SCADA system to record and store all measurement values and alarm events. This data is available in the “History” tab, where engineers can perform detailed analysis by selecting specific time ranges and identifying long-term patterns. This makes it possible not only to track events, but also to identify the causes of failures and develop preventive strategies. The archive provides full documentation of processes, which is particularly useful for audits and optimization of production processes.

The solution also offers global access - allowing staff to monitor processes from anywhere through browser-based access. This state-of-the-art approach not only increases operational flexibility, but also provides a high level of data security, protecting data from unauthorized access with end-to-end encryption and two-factor authentication.

How has SCADA improved the speed of response to failures and reduced production downtime? Customer benefits

The implementation of a SCADA visualization and mointoring system brought a number of significant benefits to Lapport Schleiftechnik, which clearly improved production efficiency and the quality of process management in industrial furnaces. One of the most important results was a significant reduction in production downtime. With real-time temperature monitoring and automatic alarms, the company has been able to respond instantly to any irregularities before they lead to more serious problems and losses.

The SCADA system has also provided an increase in production efficiency through remote access to data and the ability to respond immediately to alarms, allowing operators to manage the process on an ongoing basis regardless of location. This allows Lapport Schleiftechnik to flexibly adapt to current production needs, positively impacting workflow and reducing the risk of delays. Increased flexibility and time savings in managing industrial furnaces also contribute to improved operational safety and production quality, minimizing the risk of failures and errors.

One of the key advantages of the SCADA system is also the ability to track and archive process data. This gives the company access to historical values of temperatures and other parameters, allowing it to perform analysis and identify patterns that may indicate potential risks or areas that need to be optimized. This supports preventive measures, allowing problems to be anticipated and appropriate corrective actions to be implemented before they affect production continuity.

With all these benefits, the SCADA system has not only improved production efficiency and end-product quality at Lapport Schleiftechnik, but has also provided the company with the tools it needs to better manage resources and improve processes over the long term.

Are SCADA monitoring and visualization systems the future of industrial automation?

The implementation of a SCADA visualization system at Lapport Schleiftechnik has brought numerous benefits that demonstrate the importance of digitizing industrial processes. With SCADA, the company can monitor its industrial ovens in real time, respond to any problems almost immediately, and manage process data more effectively. Remote access to information allows flexibility in overseeing processes, while alarming and data archiving functions support preventive measures and long-term production improvement. These elements not only improve the quality of final products, but also minimize the risk of downtime, which is key to keeping production flowing.

For industrial companies that want to remain competitive in the digital age, the introduction of a SCADA system is a logical step toward full automation and digitization of technological processes. SCADA is not only a monitoring tool, but also a platform that enables more efficient management of resources, better response to irregularities and full control over complex industrial processes. For companies planning to implement such a system, SCADA offers flexibility and scalability, making it easy to adapt to different types of production, from the chemical industry to the food industry.

The system offers extensive expansion and adaptability to changing industrial requirements. Thanks to its modular design, it can be gradually developed and adapted to different production processes. Lapport Schleiftechnik is an excellent example of how SCADA can support the digitization of production and improve the quality of management. We encourage other companies to consider similar solutions that will not only improve the efficiency and quality of their processes, but also strengthen production safety and stability. In the digital age, SCADA is not just a tool - it is the key to the future of industry.

About the author

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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