Production context
- Equipment and line identifiers
- Plant or production area
- Work order
- SKU or recipe
- Lot or batch
/01 · Executive summary
Collect production data without changing machine control.
Objective
Connect existing PLCs to an industrial edge gateway and securely forward normalized operational data to AWS.
Operational boundary
Existing Siemens SMART LINE V4 HMIs and serial PLC communications remain in place. The gateway does not write to machine controllers.
Cloud outcome
AWS receives a consistent machine-data model for time-series storage, raw-data archiving, event processing, dashboards, and analytics.
Dashboard access
A secure API exposes current and historical machine data to Hunter Amenities dashboard applications.
/02 · Data requirements
A standardized operational record across machine types.
Available PLC, HMI, and production-system signals will be mapped into a normalized model. Data availability depends on the variables exposed by each machine and the source projects available during discovery.
Machine state
- Running, idle, starved, blocked
- Faulted, changeover, sanitation
- Planned down and offline
- Operating mode and speed
- State timestamps and duration
Production counts
- Good, reject, and infeed counts
- Production totals
- Yield and reject percentage
- Station-to-station losses
- Cumulative counters where available
Alarms and faults
- Alarm code and description
- Information, warning, fault, and emergency stop severity
- Start and end timestamps
- Duration
Quality data
- Checkweigher and fill-weight values
- Out-of-spec counts
- Torque and seal integrity
- Vision-system reject reasons
- Pass or fail status
Process variables
- Temperature, vacuum, and pressure
- Induction seal power
- Process setpoints
- Actual values
- Other accessible read-only signals
/03 · Proposed architecture
Edge collection, secure transport, cloud storage, and dashboard access.
An industrial edge computer connects to PLCs through Ethernet while the existing HMI serial connections remain untouched.
Read-only by design
- No PLC register writes
- No setpoint or recipe changes
- No alarm resets or acknowledgements
- No forced I/O or program uploads
Production independence
- No start or stop commands
- No control-logic changes
- Machine operation does not depend on AWS
- Buffered data forwards when connectivity returns
/04 · Scope and deliverables
Equipment connectivity through production validation.
| Workstream | Included deliverables | Completion evidence |
|---|---|---|
| Discovery | Confirm machine inventory and current networking setup, then review STEP 7 Micro/WIN SMART, WinCC flexible SMART V4, TIA Portal, and Panasonic FPWIN projects where available | Machine inventory, network topology, connection points, signal inventory, and tag-mapping plan are documented |
| Plant connectivity | Industrial gateway, Ethernet switching, cabling plan, and connectivity for supported PLCs | Selected machines are readable without disrupting existing HMI communication |
| Edge software | Siemens S7, OPC UA, and Modbus communication, normalization, local buffering, state processing, remote configuration | Mapped signals are collected, normalized, buffered offline, and forwarded after reconnection |
| AWS platform | AWS IoT Core, device certificates, MQTT with TLS, event processing, time-series data, S3 archive, machine identity | Authorized gateway data is ingested and stored using the normalized model |
| Dashboard API | Authenticated endpoints, current and historical data queries, filtering, pagination, and documentation | Dashboard use cases can retrieve agreed data through documented read-only requests |
| Validation | Production-floor state calibration, alarm mapping, counts, quality variables, documentation, and deployment configuration | Observed running, idle, starved, blocked, and faulted conditions align with recorded events |
Supported equipment includes Siemens S7-200 SMART PLCs, Siemens ET200SP and S7-1500 controllers, Siemens SMART LINE V4 HMIs, Panasonic FP-XH controllers, checkweighers, and additional compatible Ethernet, OPC UA, S7, or Modbus equipment identified during implementation.
/05 · Dashboard API
One secure interface for current and historical machine data.
The read-only API will provide consistent JSON responses regardless of PLC manufacturer. Final endpoints and refresh requirements will be confirmed during discovery.
Available data
Equipment identity, current state, historical state events, production counts, speed, alarms, quality measurements, process variables, and production context.
Query controls
Filtering by plant, area, line, equipment, work order, SKU, recipe, lot, batch, state, alarm severity, and time range.
Integration controls
AWS-based authentication and authorization, documented request and response formats, pagination, timestamps, and error handling.
{
"equipmentId": "BPG-200",
"lineId": "LINE-02",
"timestamp": "2026-09-22T14:21:00Z",
"state": "RUNNING",
"mode": "AUTO",
"speed": 42,
"goodCount": 20903,
"rejectCount": 37,
"fault": false
}/06 · Delivery sequence
Discovery first, then machine-by-machine rollout.
Phase 1
Discover
Confirm machines, networking, and source projects
Confirm controller types, current network topology, available switch ports, cabling routes, network access, exposed variables, PLC and HMI project availability, and the dashboard's priority data requirements.
Phase 2
Connect
Install edge and network components
Configure the industrial gateway, switches, device connections, read-only drivers, and secure device identity.
Phase 3
Normalize
Map data and derive machine states
Normalize signals, alarms, counters, and quality variables. Calibrate starved, blocked, idle, and faulted logic against floor behavior.
Phase 4
Enable
Deliver AWS services and dashboard API
Complete cloud ingestion, historical storage, API access, documentation, deployment configuration, and remote monitoring.
Key assumptions
- Authorized access to production networks and selected PLCs
- Current network topology and available connection points can be reviewed during discovery
- PLC and HMI source projects supplied where available
- Machine representatives available for floor validation
- Production or business systems provide context not present in PLCs
Estimate drivers
- Number of unique machine types
- Availability and quality of controller source projects
- Accessibility of existing variables and counters
- Machine-specific logic required for reliable state classification
/07 · Investment
Fixed price for the described implementation.
Engineering implementation$26,000 USD
Equipment and installation$6,000 USD
Total project investment, plus applicable taxes$32,000 USD
This fixed price covers the scope described above. Any requested scope changes will be quoted separately.
/08 · Next steps
Confirm the machine inventory and current networking setup.
Machine inventory · Network topology · Signal priorities
- Confirm the initial machines, production lines, and controller types included in the rollout
- Review the current networking setup, available switch ports, cabling routes, and required connection points
- Provide available PLC and HMI source projects for review
- Define dashboard API priorities, access model, and refresh expectations
- Approve a detailed statement of work with final scope, schedule, and payment milestones