1. The Problem

A mail order pharmacy operations relied on legacy SCADA applications for KPI reporting. These applications failed modern security audits (including Veracode) and lacked flexibility for real-time downtime, OEE, and event monitoring. The fragmented system created compliance risks, delayed KPI visibility, and limited scalability for enterprise-wide deployment.

2. The Solution:

FrameworX was implemented to modernize KPI reporting and provide a secure, scalable enterprise platform. A key enabler was the FrameworX Edge project acting as a Calculation Engine, which processes raw PLC data in real time before passing it into GE Historian. This enabled advanced downtime and OEE calculations at the edge, reducing historian load and improving overall system responsiveness. The solution included secure local data collection, Windows Server infrastructure, and integrated dashboards for downtime, OEE, and event monitoring.

Simple Architecture Diagram:

OPC UA Server (Tags Published) MES System Factory Studio Edge (Edge License) Factory Studio Higher-Level (Dashboard) Over 50 client connections Direct FS Driver Rockwell PLCs (Multiple) For MES system XML Files (Parsed into Tags) From Filter System for MES iFix Client (OPC DA) For Dashboard 14 iFix SCADA Nodes


Technical Specifications:

  • PLCs: Rockwell Automation (including custom controllers)
  • Database: Microsoft SQL Server (existing CVS SQL)
  • Historian: GE Historian 6.0
  • Servers: Windows Server 2021 R2 (App Server 1: Local Engine & Edge Calc Engine, App Server 2: Portal & Monitor)
  • Architecture: Edge data collection and calculation engine feeding historian and SQL-based event monitor
  • Integration: FrameworX Edge → GE Historian → SQL MES Event Monitor

  • MES is referring to a pharmaceutical MES.

3. Key Enablers:

  • Edge Project as Calculation Engine: Real-time KPI and downtime/OEE calculations at the edge, minimizing historian overhea
  • Secure Enterprise Deployment: Passed modern security audits where legacy systems failed
  • Templated Asset Types: Rapid deployment of new assets and consistent data models across facilities
  • Integrated Dashboards: FrameworX Portal & Monitor providing real-time MES event monitoring with SQL integration

4. The Results:

  • Delivered real-time KPI visibility for downtime, OEE, and security metrics critical to pharmacy operations
  • Reduced compliance risk by passing stringent security screening and Veracode testing
  • Optimized historian performance by shifting calculations to the edge
  • Enabled consistent, scalable deployment across multiple facilities with standardized asset templates