High-mix lines that change model without losing takt — and trace every single part.
Automotive and e-mobility mean high mix, frequent model changeovers, multi-axis kinematics, and OEMs that demand per-part traceability. We build the line automation and the MES/SCADA software that keeps the takt the market demands and documents every station — from raw material to tested part — ready for the customer's audit.
Four recurring knots we see on assembly lines and new e-mobility lines. They usually coexist on the same line.
Model changeover that eats the takt
Daily mix across variants, long manual changeovers, SCADA with no structured recipe management: every new model becomes a PLC intervention instead of a configuration. Productivity collapses exactly where the market asks for flexibility.
Per-part traceability required by the OEM
The OEM won't settle for the lot: it wants the single part's genealogy — materials, process parameters, test results — recallable in an IATF audit and during a recall campaign. Excel and hand-signed sheets don't hold up.
Multi-axis kinematics and safety
Winding and assembly run on dozens of synchronous axes in virtual camming and gearing, with minimal margin for error. Functional safety must be documented for the audit, not bolted on afterwards: the PLC has to know when it may NOT restart.
Multi-station lines, different vendors, no coordination
Ten to twenty stations from different vendors have to behave as a single line, with shared takt and diagnostics. Without an orchestrator, each station is an island and the root-cause of a line stop becomes a blame hunt.
One team from PLC to line dashboard — no handoffs between mechanical integrator, software house, and SCADA vendor with misaligned SLAs.
PLC, multi-axis motion control, and safety
Siemens PLC programming (S7-1500, S7-1500T for motion), synchronous motion on V90/S210/S120 with virtual camming and gearing for winding and assembly. Offline simulation to cut field commissioning. ISO 13849 / IEC 62061 safety documented for audit.
Robotics and machine vision in line
Fanuc, KUKA, and ABB robot cells for palletizing, machine tending, and handling, integrated with the PLC. Cognex and Keyence machine vision for in-line quality and robot guidance — inside the line logic, not bolted on beside it.
ARIA MES/SCADA: orchestration and per-part traceability
ARIA coordinates the distributed stations as one line, records the single part's genealogy (materials, parameters, test results), computes OEE, and runs the Andon. Model changeover goes through a recipe: the PLC stays the source of truth, ARIA observes and records.
IT/OT integration and OT cybersecurity
Production data to the OEM's MES and ERP via OPC UA and a secure API. OT networks segmented per IEC 62443 — often required by the large groups' supplier audits and by NIS2: IT/OT convergence without opening doors to threats.
We build automation with the requirements the OEM and its auditor want to see.
- IATF 16949
- VDA 6.3
- ISO 9001
- Traceability / part genealogy
- DMC / GS1 marking
- ISO 13849 / IEC 62061 (safety)
- Machinery Directive 2006/42/EC (CE marking)
- IEC 62443 (OT cybersecurity)
- NIS2
Projects we actually delivered. We name the client when they authorize it; otherwise the case stays anonymous, and detailed figures are shared in calls.
- Challenge
- CM builds the individual stations for stator production: core-stack forming and insulation, coil winding and insertion, end-turn forming, terminal connection, banding, electrical testing. What it had to deliver its e-mobility customer, though, was a line — not a fleet of machines. Over 15 independent stations, each with its own controller, and heavy kinematics to coordinate without rewriting the process know-how built into every machine.
- What we did
- Each station keeps its own PLC — the S7-1516TF on the critical ones — but the line runs from a single layer. ARIA SCADA pulls part traceability, andon, and OEE from every station, with status visible per station. Network and servers behind the software layer stay with IOMA.
- Result
- Required industrial-plan takt reached on schedule. Faulty-component identification down from hours to minutes with the unified dashboard. Two twin plants now run on the same line configuration, with no PLC code rewritten.
- Challenge
- This is the classic pain point on high-mix automotive lines: without structured recipe management, every new model means opening the PLC code and recompiling. Here, changeover stayed manual at 45 to 90 minutes on a legacy SCADA. IOMA stepped in after a first attempt by another supplier had already stalled the project.
- What we did
- Flexibility comes from moving configuration out of the PLC code. ARIA SCADA manages the multi-product recipes on top of a Siemens S7-1515T PLC: model changeover is a recipe selection, not a code rewrite. Network and servers behind the software are IOMA's responsibility.
- Result
- Line in production after standing idle following a failed first attempt. Format changeover from over 45 minutes to under 8, with new variants addable as master data in the ERP: zero PLC code written for new models after go-live.
- Challenge
- Nide Wintech sells machines and lines for electric-motor production to manufacturers worldwide. Its customers were asking for two things at once: supervision that matched the quality of the machines, and machines that met Industry 4.0 requirements. No label satisfies that on its own: it calls for real interconnection to the factory's IT systems, continuous monitoring of process parameters, and remote diagnostics.
- What we did
- The Industry 4.0 requirement gets met on board the machine, not as a later integration. ARIA SCADA ships standard on stand-alone machines and lines the builder sells, with historized parameters and remote diagnostics. Interconnection to the end customer is already part of the supply; network and servers behind the software stay with IOMA.
- Result
- The builder never had to open a software department to offer supervision that matched its own machines. Its customers signed their machines off as Industry 4.0 compliant, finding interconnection, monitored parameters, and remote diagnostics already installed at delivery.
What teams ask before we kick off.
Do you handle complex multi-axis kinematics (virtual camming, gearing)?
How do you implement the per-part traceability the OEM requires?
Do you integrate with the OEM's MES/ERP systems?
Do you help us pass the IATF 16949 / VDA 6.3 audit?
Do you work on existing lines or only new ones?
Which PLCs and robots do you use?
Pages usually opened after this one.
Industrial robotics
Fanuc, KUKA, ABB and machine vision: robotic cells integrated with the line, not islands of their own.
Go to industrial robotics →ARIA Suite
MES/SCADA, HMI, Warehouse, and Mobile as a single platform. Already in production on multi-station lines.
Explore ARIA →PLC programming
Siemens S7-1500, motion control, safety. The layer underneath every MES and SCADA we build.
Go to PLC programming →Got a project in mind?
Describe the line and the problem on a 30-minute technical call: we tell you straight away whether it's in our wheelhouse. We typically reply within 24 hours. From the first call to commissioning, you speak to the same person.