From industrial networking systems, data collection , reporting systems, full SCADA build/deploy to PLC Programming at the bottom of the production automation stack, Program4 Engineering, Inc. can handle your requirements for Network Infrastructure, Production Reporting, Manufacturing Control, Process Management.

We apply true Software Engineering principles to the design and development of the whole pyramid, including the infrastructure. IT department responsibilites stop at your production door? We bring continuity.

Whether you need a turnkey solution, improvements and support for existing systems, or additional engineering expertise to supplement your in-house staff, Program4 can provide the solution, for a specified price, on a quoted "Not to Exceed" basis, or an hourly consulting contract.

Detailed Production Reporting is key to production optimization and comprehensive process analysis. Program4 Engineering has developed a range of Data Collection and Reporting systems to suit individual plant requirements. Our systems can provide:

	Collection of process data from PLC and existing instrumentation on process event or timed basis using:
		PlantLogicsm data collection tools developed by Program4.
		Commercial packages such as Rockwell Software's RSSql ® or Wonderware's Industrial SQL Server ®.
		Virtual Server Installations
		Existing SCADA / HMI.
	Microsoft ® and Oracle® databases and servers to reliably store process data, with reliable data backup proceedures.
	Operator entry screens to capture test results, downtime reasons, operator actions, etc.
	Security features to limit access to sensitive data to authorized personnel.
	Data presented in summary reports, detailed tables, or graphs.
	Production shift reporting, batch reporting, lot tracking , QC data.
	Flexible Batching Recipe Systems: any ingredient in any order.
	Reports based on production equipment (Machine, Line).
	Options for presenting the collected data:
		Integrate data & metrics to SAP, MES, Key Performance Indicator systems
		Web Server-browser based reports accessible from any desktop on your network. No per seat liscense. Secure access for configuration.
		Have a Visual Basic® and/or Microsoft Access® reporting interface? We can do that. (Compiled application required at point of use.)
		Reports also provided within an existing SCADA / HMI for your operators/supervisors.

Real time production data is critical to quantify productivity, determine resource allocation, and monitor process efficiencies. A range of approaches are available from Program4 to transport and translate data from the production floor to the front office. Contact us for details regarding your process.

At Program4 Engineering, Inc IT is a core competency. Networking in a running production environment presents unique impact considerations. Our history in automation manufactuing brings you the experience needed to design and implement stable industrial-duty production networks. Existing infrastructure, expansions and new plant constructions: we can enable IT all the way to your controllers.

	Industrial Network Design & Installation		Virtualization technologies
	Oracle and Microsoft SQL database servers		Web-Based PlantLogic Manufacturing Knowledge Systems
	Server/ client, thin client,peer to peer architectures		Industry standard tools & techniques
	Ethernet LAN,VLAN, VPN. VoIP integration		Microsoft®, Unix

 

Program4 Engineering, Inc. excels at SCADA (Supervisory Control And Data Acquisition) and HMI (Human-Machine Interface) programming, with experience in all of the major packages. We do upgrade migrations.

	GE/Fanuc (Intellution) iFIX ® and FIX32 ®		Secure Insustrial Network Design & Installation: LAN, VLAN
	Rockwell Automation Factory Talk ® ,RSView ®		Solutions Provider
	Invensys Wonderware InTouch ®		Redundant production server/ virtualizattion implementations

User interface design is not an afterthought at Program4. We incorporate technical illustration in the design process to combine data display and operator control into a visually streamlined and functionally consistent environment. Working from instrumentation diagrams, plant layouts, and other customer-provided reference material, we design an intuitive easily-navigated set of display pages, using a standard set of images and icons.

The end result allows the operators, supervisors and engineers to monitor and control the process with a high degree of understanding and a minimum of error. From experience, we know that when operators enjoy such an environment, you benefit from reduced downtime and increased throughput.

 

PLC Programming and Installation are at the heart of Program4 Engineering, Inc.'s efforts to increase manufacturing efficiency for its clients. Our staff has extensive PLC design, programming, installation, troubleshooting and commissioning experience.

Program4's structured standards and programming techniques such as State Logic programming deliver stable, reliable and maintainable PLC systems. Turn to Program4 Engineering for your PLC system design and programming needs:

	A-B PLC and ControlLogix ®		A-B DH+ and ControlNet Networks
	Modicon ® Telemecanique™		DeviceNet Networks
	Honeywell		LAN, VLAN Ethernet Networks
	GE/Fanuc		Structured Code Development
	Omron		State Logic Programming
	Siemens / TI		Rigorous documentation standards
	Koyo's Automation Direct PLC		Simulation Testing in our Facility

The engineering staff at Program4 Engineering, Inc. has a broad range of experience in Electrical and Mechanical Engineering. Our staff has been involved in the design of hardware systems for applications including pick-and-place robotics, motion control systems, professional sound reinforcement, and electrical distribution, network wiring and computer rooms. By combining our own staff and a select number of Mechanical Engineering partners, Program4 Engineering, Inc. can provide:

	Power Distribution Design		Network Design and Installation
	I/O Schematics		Plant Equipment Layout & Specification
	Instrument Specification		Machine Design

Oue facility includes a full-service Panel Shop. Program4 provides a full range of quality control panels and equipment enclosures. Let us quote and build from your drawings or use our in-house design team.

We incorporate the latest practices in Electromagnetic Noise Suppression and Safety, as outlined in the latest EC Directives, as well as a solid adherence to National, State and Local Electrical Codes.

	PLC Enclosures		Drive Cabinets
	Modular Remote I/O Enclosures		Operator Consoles
	Flex-mount Operator Interface Enclosures		Computer and Network Cabinets

 

At Program4 Engineering, we firmly believe that "The job isn't finished until it is documented and tested". Accurate, readable documentation is essential at every step of the design cycle. Typical documents produced and maintained during the design cycle include...

	Flow Charts & Timing Diagrams		Tabular I/O & Alarm Lists
	Software Requirements		Programming Specifications using Psuedo Code
	Interface Specifications		Database Listings (SCADA Systems)
	Database Design Specifications		Fully Annotated Program Code
	Functional Specifications

In addition to design-related documentation, Program4 Engineering, Inc. can provide...

	Technical Writing Services		Validation Protocols
	Operator Manuals		Maintenance Manuals
	Test Plans		Training Manuals

Program4 Engineering, Inc. maintains an in-house CAD department with extensive experience in producing engineering documentation for control system projects.

	Autodesk Autocad®, Bentley Microstation®		Electrical control systems document packages
	Architectural control wiring, sensors & equipment placement drawings		Network & schema system architecture diagrams
	Process & Instrumentation Diagrams (PIDs)		Mechanical/electrical design documents: enclosures. panels, operator stations, handbuttons

Program4 Engineering, Inc. has the capability to evaluate and document existing systems and processes. When a process is modified over the years, often the original documentation is not kept up to date, gets lost, is corrupted or destroyed. Turnover of staff, retirements and down-sizing often mean that the person or persons who installed and maintained your critical systems may no longer be available to explain where or why modifications have been made.

Changes and alterations to such undocumented or incorrectly-documented systems can lead to mystifying malfunctions, and often equally mystified maintenance technicians and plant engineers. Downtime translates to lost profits.

Very often the initial stage of an upgrade or expansion project is to review and document existing code and other documentation in a process we (jokingly) refer to as "Industrial Archeology" in which we attempt to determine the intent of the original programmers. Program4 can apply these research and documentation skills to existing systems to produce annotated code, pseudo-code program design documentation, functional specifications, interface specifications, database design documentation, and operator and maintenance manuals.

Our technical writing and documentation department produces high-quality documents in clear, concise, everyday English. (This web site is created & maintained entirely by our staff.)

©2008 Program4 Enginering, Inc. All Rights Reserved. PlantLogic is a Service Mark of PlantLogic, Inc.
All product names contained herein are the TM or ® of their respective holders.