Implementation of COPA-DATA zenon SCADA for Manufacturing
Centralized monitoring of processes, alarms, and machine data in a single SCADA system
Are your machines running, but the data is scattered across operator panels, controllers, local workstations, and spreadsheets?
COPA-DATA zenon helps consolidate the entire process within one SCADA system. Operators and process engineers can monitor statuses, alarms, parameters, historical data, and reports without having to check each machine separately.
At explitia, we support COPA-DATA zenon implementations wherever improved process supervision, PLC integration, MES connectivity, or reporting-ready data is required.
Let's see what Zenon can streamline in your plant!
Tell us about the day-to-day challenges in your production operations and your data sources, and we will help you choose the best application for the COPA-DATA solution.
Is COPA-DATA Zenon right for you?
The answer is most likely yes, especially if:
You want a central overview of production
Machine data is only available locally
There is no history of process parameters
You need to connect SCADA to PLC, MES, ERP, or a database
You want to report on production based on machine data
Alarms and events need better visibility
COPA-DATA Zenon as a SCADA system
Zenon is a SCADA system for visualizing, monitoring, and controlling industrial processes. It most often runs on a PC and sits between the machine layer and business systems.
It can operate in a control room, at an operator station, in the engineering department, or anywhere continuous process supervision is required.
What can a COPA-DATA Zenon implementation include?
| Real-time process visualization |
| Data acquisition from machines and PLC controllers |
| Alarms, trends, and parameter history |
| Production reporting |
| Process control from the SCADA level |
| Production order handling |
| Integration with higher-level systems such as MES or ERP, databases, and reporting systems |
Zenon integration with PLC controllers
PLC controllers are Zenon’s data source and communication point with the process.
Typical setup:
Machine → PLC controller → COPA-DATA Zenon SCADA → MES / ERP / reports
Zenon does not replace the PLC. The controller remains responsible for the machine, while Zenon provides broader supervision, visualization, data history, and connectivity to other systems.
Visualization, alarms, and historical data
A properly configured SCADA system helps you see the process without guesswork. From one place, the operator can check the machine status, alarm, parameter, trend, order, or PLC data.
In COPA-DATA Zenon projects, Zenon Historian and Zenon Logic may also be used. The former helps store historical data and create reports, while the latter can handle some logic tasks on the SCADA system side.
What does our Zenon integration process look like?
- we identify the data sources,
- we connect Zenon to PLC controllers,
- we configure variables, alarms, trends, and screens,
- we prepare communication with MES, ERP, or databases,
- we enable reporting,
- we test the system in production.
Let's discuss implementing COPA-DATA Zenon in your plant!
Organize your production data and turn it into a valuable production management tool. Contact us, and we will help you plan the next steps.
When does implementing COPA-DATA Zenon make the most sense?
Let’s talk if:
- you have several machines, lines, or workstations,
- you want to view the process from one place,
- you need data history and reports,
- you want to link production to orders,
- you are planning integration with MES, ERP, or databases,
- production data needs to be sent to reports or the Production Portal.
What can you gain from implementing Zenon?
The key benefits include:
| A real-time process overview in one place |
| Data history for analyses and reports |
| Less manual information gathering |
| Alarms, trends, and parameters for operators |
| Control of selected process elements |
| Data ready for use in MES, ERP, reports, or the Production Portal |
What does the collaboration process look like step by step?
The implementation process includes several stages:
Objective
Data sources
Implementation scope
SCADA application and testing
- Objective: we determine what you want to monitor, what you want to control, and what data is needed.
- Data sources: we check the PLCs, machines, MES, ERP, databases, or other sources.
- Implementation scope: we define the screens, alarms, reports, integrations, and how users will work with the system.
- SCADA application and testing: we build the system, connect it to production, and verify that it works.
What should you prepare in advance?
The following will be useful:
| Process description |
| List of machines, lines, or areas |
| Information about PLC controllers |
| Alarm and reporting requirements |
| Information about MES, ERP, databases, or reports |
| Contact details for technical personnel on your side |
You do not need a complete specification. To get started, it is enough to know what you want to see, what you want to control, and where the data should go next.
COPA-DATA Zenon as part of the production system
Among other things, we integrate Zenon with:
Let’s see what COPA-DATA Zenon can streamline in your production operations
Tell us which machines, controllers, and systems operate in your plant. We will explain what data can be collected, where it should be displayed, and where it is best to start.
Schedule a consultation about COPA-DATA Zenon.