Why is SCADA visibility critical in material handling systems?

SCADA visibility enables supervisors to monitor multiple conveyor zones in real time, identify emerging issues, and respond before faults disrupt operations.

What is alarm rationalisation?

Alarm rationalisation structures and categorises alarms so they are meaningful, prioritised, and actionable rather than overwhelming or ambiguous.

How did this project reduce reactive maintenance?

By improving system visibility, integrating PLC zones, and introducing structured alarms, maintenance teams could identify and resolve issues proactively.

What measurable improvements were achieved?

The project delivered faster fault response, improved shift visibility, reduced reactive call-outs, and more accurate reporting.

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Material Handling Automation Case Study

Improving SCADA Visibility Across a Distribution Facility

Stratos Control Systems delivered a SCADA visibility and multi-zone integration project to help a distribution facility move from reactive response to proactive control. By redesigning SCADA, rationalising alarms, and improving zone integration, supervisors gained real-time insight across shifts and faster response to conveyor faults.

01

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The Problem

The facility operated multiple conveyor zones with poor system-wide visibility and limited alarm categorisation.

Maintenance response was largely reactive, and supervisors lacked real-time data across shifts, making it harder to prevent small issues from escalating into disruption.

02

Scope of Work

Phase 1 – Visibility & Alarm Review

Stratos assessed SCADA visibility, fault data quality, and alarm structure across conveyor zones.

This included:

Review of SCADA screens, tags, and zone coverage
Assessment of alarm structure and categorisation gaps
Review of fault response patterns and escalation triggers
Identification of integration requirements between zones

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Phase 2 – SCADA & Integration Strategy

A structured approach was developed to improve visibility, consistency, and response time across the full system.

The strategy included:

SCADA redesign for clearer operational visibility
PLC integration across zones for consistent behaviour
Alarm rationalisation and structured categorisation
Performance dashboards for faster shift-level insight

Phase 3 – Implementation

Stratos implemented the upgrades and aligned the system presentation to operational needs across teams and shifts.

Implementation included:

SCADA rebuild and improved navigation
Cross-zone PLC integration and consistency improvements
Structured alarm framework deployment
Dashboards and reporting improvements for supervisors

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03

Platforms Used

The project utilised modern automation and control system technologies, including:

Mitsubishi PLC
Ignition SCADA
Structured alarm framework

These technologies provided improved system reliability, visibility, and maintainability.

04

Outcomes & Metrics

Key outcomes included:

60% faster response to conveyor faults
Improved shift visibility and supervisor control
Reduced reactive call-outs and better prioritisation
Improved reporting accuracy and clearer fault patterns

Testimonial

“The improved SCADA visibility transformed how we manage the system. We now see issues before they escalate.”

Operations Manager

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Frequently Asked Questions

Gain Real-Time Conveyor Visibility

Improve SCADA visibility and fault response with Stratos Control Systems, enabling faster decision-making and more proactive management across conveyor zones.

Speak to an Automation Specialist