Vietnam Manufacturing Line PLC Upgrade | SENTRADO
A detailed case study of SENTRADO's industrial automation solution delivering measurable results for manufacturing operations in Vietnam.
Project Background & Objectives
A growing manufacturing company in Vietnam's Binh Duong province engaged SENTRADO to upgrade the control system on their primary production line, which had been running on a legacy PLC platform for over 12 years. The old system used proprietary communication protocols that could not integrate with the company's new manufacturing execution system (MES), preventing real-time production monitoring, quality tracking, and overall equipment effectiveness (OEE) analysis.
The production line performs automated assembly, testing, and packaging of consumer electronics components, with cycle times measured in seconds. The legacy controller, while functional, lacked the processing power for the advanced motion control required by a new high-speed handling system, and its proprietary network made it impossible to connect barcode scanners, vision systems, and other smart devices needed for Industry 4.0 capabilities.
SENTRADO delivered a complete control system migration to Siemens S7-1200 controllers with a PROFINET network backbone, enabling seamless integration with the MES, new motion control hardware, and a comprehensive HMI/SCADA system for production visibility. The migration was completed during a planned two-week production shutdown with all systems validated before resuming full output.
Problems We Had to Solve
1. Protocol Incompatibility
The legacy PLC used a proprietary serial protocol that could not communicate with modern industrial networks. The MES integration required OPC UA connectivity, and the new vision system and barcode scanners only supported PROFINET and EtherNet/IP.
2. Motion Control Requirements
A new high-speed pick-and-place system required precise multi-axis motion coordination with microsecond-level synchronization, beyond the capability of the legacy controller. The client needed PROFINET IRT (isochronous real-time) for deterministic motion control.
3. Minimal Shutdown Window
The production line operates six days a week with high utilization. The client could only afford a two-week shutdown for the complete migration, including installation, wiring, programming verification, and production validation.
4. Product Tracking Gaps
Without barcode-based tracking, the plant could not trace individual units through the assembly process. Quality issues were only detected at final test, making it difficult to identify the root cause of defects or implement corrective actions.
5. OEE Visibility
The plant manager had no automated way to calculate OEE. Downtime reasons, changeover times, and production counts were recorded manually on paper, leading to inaccurate and delayed performance reporting.
Our Approach & System Architecture
SENTRADO replaced the legacy control system with a Siemens S7-1200 platform using a CPU 1215C as the main controller, connected via a PROFINET IRT network to distributed I/O, servo drives, HMI panels, and third-party devices. The PROFINET IRT network provides the deterministic communication required for synchronized multi-axis motion control, with cycle times under 1 millisecond for the motion coordination between the pick-and-place axes.
An OPC UA server embedded in the S7-1200 provides a standardized, secure data interface to the MES, transmitting production counts, cycle times, quality results, downtime events, and OEE metrics in real time. Barcode scanners at each station read unit identifiers and pass them to the PLC, which tracks each product through the assembly sequence and records process parameters and test results against that serial number in a local data log.
The HMI system includes two SIMATIC Comfort Panels at operator stations plus a WinCC RT Advanced SCADA workstation for the production supervisor. The SCADA provides real-time OEE dashboards, Pareto charts for downtime analysis, production scheduling, and quality trend charts. The control panels were manufactured at SENTRADO's facility with all VFDs, servo drives, and power distribution pre-wired and tested, minimizing on-site installation time during the two-week shutdown window.
System Architecture Highlights
- Siemens S7-1200 CPU 1215C with PROFINET IRT
- PROFINET IRT network for deterministic multi-axis motion
- OPC UA server for standardized MES integration
- Barcode-based product tracking at every assembly station
- V90 servo drives with SINAMICS for pick-and-place motion
- WinCC SCADA with real-time OEE dashboards
- Pre-wired panels for rapid installation during shutdown
- Vision system integration via PROFINET
System Parameters & Configuration
| Control System | Siemens SIMATIC S7-1200 |
| Controller | 1 × CPU 1215C DC/DC/DC |
| Total I/O Points | 280+ (AI: 24, AO: 8, DI: 160, DO: 88) |
| Motion Axes | 4 × servo axes (PROFINET IRT) |
| Communication Protocol | PROFINET IRT / OPC UA / Modbus TCP |
| HMI Panels | 2 × TP700 Comfort + 1 SCADA workstation |
| Control Cabinets | 2 × IP54 |
| Servo Drives | 4 × SINAMICS V90 (1.5kW) |
| Cycle Time | 8 seconds (reduced from 14 seconds) |
| MES Interface | OPC UA with encrypted connection |
| Product Tracking | Barcode at 6 stations |
| OEE Monitoring | Real-time automated calculation |
Key Components & Hardware
Siemens CPU 1215C
6ES7215-1AG40-0XB0
Main line controller
SINAMICS V90 Servo
6SL3210-5FB10-1UF0
PROFINET servo drive
SIMOTICS S-1FL6
1FL6042-2AF21-1AA1
Servo motor for pick-and-place
TP700 Comfort HMI
6AV2124-0GC01-0AX0
Operator touch panel
WinCC RT Advanced
6AV2104-0DA06-0AA0
SCADA with OEE option
SCALANCE XC208
6GK5208-0BA00-2AC2
PROFINET IRT switch
SITOP PSU6200
6EP3333-7SB00-0AX0
24V/10A stabilized power supply
SIRIUS 3RT2 Contactor
3RT2025-1BB40
Motor contactor with auxiliary contacts
Project Phases
Design & Programming
6 weeksHardware spec, software development before shutdown
Panel Manufacturing
3 weeksPre-wired panels fully tested at SENTRADO
Pre-Shutdown Preparation
2 weeksCable trays, network infrastructure, MES setup
Shutdown Week 1
1 weekRemove old system, install new panels, wiring
Shutdown Week 2
1 weekPower-on, I/O checks, dry runs, production validation
Post-Startup Support
4 weeksOn-site engineer for optimization and tuning
Training
1 weekOperator and maintenance team training
Ongoing Support
12 monthsRemote diagnostics and warranty service
Measurable Outcomes
Performance data verified after system commissioning and sustained operation.
From 14s to 8s per unit
Real-time production data visibility
Automated OEE and quality tracking
Station-level traceability and early detection
Before vs After: Quantified Comparison
| Metric | Before | After | Change |
|---|---|---|---|
| Cycle time per unit | 14 seconds | 8 seconds | −40% |
| MES integration | Standalone machines, no data | 100% real-time MES integration | Connected |
| Manual data entry | Paper-based OEE tracking | 0 manual entry (automated) | −100% |
| Defect rate | Baseline | 30% reduction (early detection) | −30% |
| Production visibility | End-of-shift summary | Real-time OEE dashboards | Live |
Data based on project commissioning reports and sustained operational measurements. Client name available under NDA.
Bottom Line Impact
The delivered automation system exceeded all performance targets specified in the contract, achieving higher throughput, lower energy consumption, and improved product quality compared to the baseline operation. The client reported full return on investment within the projected payback period and has since engaged SENTRADO for additional plant expansion phases.
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