How KASKO connected sensors on 42 machines to its MES system and reduced downtime and scrap rates

As part of its efforts to streamline production, KASKO was looking for a way to expand data collection to include data from sensors retrofitted to dozens of injection molding machines. The goal was to find the simplest possible way to feed the data into the PHARIS MES system. The solution was the OPC Kepware Server, which now connects dozens of devices across the company. It helps the MES system prevent downtime and the production of defective parts, while paving the way for further development in production digitalization.

Communication interface complementing basic data collection

At KASKO, sensors communicating via the Modbus protocol were added to 42 injection molding machines. The company wanted to send sensor data to the MES system and was looking for a simple solution that would accelerate further digitalization of the company in the future.
“We first tested the OPC Kepware Server on a single device. It proved successful, so we expanded it to another 41 devices. Along with the license, we also used technical support from FOXON,” explains Ing. Petr Haloda, Process Engineer at KASKO.

Thanks to the OPC server, the company gained a single communication interface between the sensors, production equipment, and the MES system, eliminating the need to handle each new connection individually.

Data helps prevent problems

Today, KASKO uses approximately 400 active tags to optimize production. Thanks to the synergy between the MES and Kepware Server, the company continuously monitors not only key production data from the MES, but also parameters that are important for smooth production. The system alerts operators to situations that could lead to downtime or the production of defective parts.

“We try to detect a problem before it actually occurs. Operators receive alerts in time and can intervene before production comes to a halt.”
Ing. Petr Haloda, Process Engineer at KASKO

Kepware Server has proven useful, for example, in monitoring material loaders or checking material coloring. In the event of a shortage of input material or incorrect dosing, the MES alerts operators in time, before the problem occurs.

Connecting additional devices is now easier

The value of Kepware Server also became clear when building a new production line. Thanks to the infrastructure already in place, KASKO was able to easily connect additional devices communicating via Modbus — in this case, tightening screwdrivers.

„Adding another new device is now just a bonus for us, one that we benefit from thanks to our initial investment in the Kepware Server system.”
Ing. Petr Haloda, Process Engineer at KASKO

Today, the company uses only a smaller part of the OPC server’s capabilities. Even so, it is already obtaining all the valuable data it needs from production equipment, its own stations, and other systems.

Training at FOXON Academy opened up further possibilities

After one year of operating the OPC server, Process Engineer Petr Haloda completed professional training in OPC communication at FOXON Academy. Thanks to a better understanding of communication principles and server configuration, he gained greater confidence in further developing the solution.

„The training had enormous added value for me. Until then, we had been using settings that met our basic requirements, but it was only there that I understood how it actually works. That opened up further possibilities for using the software.“
Ing. Petr Haloda, Process Engineer at KASKO

They tested everything before purchasing the OPC server

Before purchasing the license, KASKO used the free trial version. This allowed the company to verify the functionality of the solution in real production without the risk of an unnecessary investment.

„We found that it was exactly what we had expected. It worked reliably, and there was nothing left to discuss — we decided to go for it.“
Ing. Petr Haloda, Process Engineer at KASKO

The result?

• Connection of 42 injection molding machines and other devices to the MES system
• Approximately 400 active tags for data collection and evaluation
• Early detection of problems before production is interrupted — higher efficiency and OEE
• Lower costs compared to connecting devices individually
• Easier expansion to new machines and technologies
• Stable operation and access to technical support

„I definitely don’t regret this purchase. It’s a huge bonus and advantage. It works for us, and I don’t have a single negative comment about the software,“ says Process Engineer Petr Haloda, summarizing his experience.

Try Kepware Server in your production environment for free

Do you need to connect PLCs, machines, production lines, or an MES system and collect data from various devices without complex integrations?
Download the free trial version of Kepware Server. Simply click Download software on the product page and see what it can do using your own data.

✔ Test communication with your devices.
✔ Try out a wide range of supported protocols.
✔ Verify the stability of the solution in real operation.
✔ Only then decide whether the license makes sense for you.

I want to try Kepware Server for free

KASKO spol. s r.o. is a Czech family-owned company founded in 1992 and based in Slavkov near Uherský Brod. It specializes in the production of plastic parts for the automotive industry, as well as the development and production of injection molds. The company employs more than 350 people and places strong emphasis on quality, innovation, automation, and long-term sustainable development.