Consumer Products Manufacturer Factory Modernization

Salas O’Brien collaborated with a consumer products manufacturer to upgrade its legacy RSView32-based operator interfaces (HMI) controlling two production sites to Rockwell’s FTView platform for the client’s largest facility in the Americas. Additionally, we upgraded the batch server applications (FTBatch) to accommodate the client’s latest IT-approved operating systems. The project’s goals were to ensure seamless integration with the new operating system, maintain operational efficiency, and upgrade cybersecurity compliance while requiring zero downtime during the upgrade process.

Our upgrade plan transitioned 46 operator interfaces and batch servers to modern virtual machines (VMs) with thin clients, implemented cybersecurity measures, and additional data integration. Our efforts led to enhanced efficiency, cybersecurity compliance, future scalability, continuous production, and reduced operator dependence. Ultimately, the modernization positioned the client for long-term operational success and technological adaptability.