End-to-End Traceability and
Process Control in the Coating Line
At Phinia's facility in the Izmir ESBAS Free Zone, loading and coating operations were made fully traceable on a bar/rack and batch basis.
Bar/rack and batch visibility in coating operations
Phinia's manufacturing facility in the Izmir ESBAS Free Zone serves the automotive industry.
Within this project at the coating plant, loading and coating operations were digitized and managed through bar/rack and batch relationships.
Reliable control of loading rules and recipe compliance
The plant needed a reliable way to manage which product was loaded onto which bar/rack, which bar/rack belonged to which batch, and applicable loading constraints. Manual handling introduced risks of incorrect loading, recipe mismatch, and traceability gaps.
- 01Complex MappingManual tracking of bar/rack-product-batch relationships was error-prone.
- 02Constraint EnforcementProduct group, min/max loading limits, and recipe conditions had to be enforced consistently in operations.
PLC-integrated bar/rack and batch traceability over OPC-UA
Direct communication with the PLC was established via OPC-UA. Bar/rack data captured at the loading station was matched with real-time batch data, bar/rack IDs were retained on batch records, and authorized loading conditions were managed through a central panel.
Bar/Rack and Batch Matching
Bar/rack data read at loading is matched with live batch information in the predefined format.
Rules and Recipe Setup
Bar/rack-product mappings, product groups, min/max limits, and PLC recipe relations are configured in the panel.
Conditional Loading
Loading at coating entry is validated against approved rules and product quantity is sent to PLC for surface-area calculations.
Exit Result Tracking
At coating exit, bar/rack and batch records are linked with result data and stored.
C# SCADA, OPC-UA, barcode scanners, and PLC infrastructure
C# SCADA Application
Manages bar/rack-batch matching, rule validation, data flow, and traceability records.
OPC-UA Protocol
Provides reliable real-time data exchange between SCADA and PLC.
PLC and Recipe Control
Controls shop-floor workflows, recipe mapping, and loading validation.
Barcode Scanners
Read bar/rack and product identifiers to initiate validated operations.
Administration Panel
Centralizes bar/rack-product mapping, product groups, loading limits, and recipe definitions.
End-to-end data flow with OPC-UA and Oracle
The system integrates with the shop-floor PLC over OPC-UA and with Oracle on the enterprise side. Bar/rack, batch, recipe, and loading data are acquired through OPC-UA, while traceability and result data are shared centrally in Oracle.
Reliable process governance and full traceability
Bar/Rack and Batch Traceability
Loading and coating processes became fully traceable at bar/rack and batch level.
Rule-Based Loading
Only approved loading operations were allowed using product group checks and min/max limits.
Higher Process Reliability
PLC recipe mapping and direct OPC-UA communication reduced operational mismatch risks.
Meet Our End-to-End Traceability Solution
OnSuite Trace allows you to manage all your production processes from a single platform. We provide end-to-end digital traceability for your business with the motto "Continuous Control, Zero Defects".
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