Automotive Migration & Systems Integration

Legacy-to-Modern Migration: OEE Increase and Digital Transformation for a Tier 1 Supplier

In the automotive industry, the reliability of control systems is a primary driver of competitiveness. For a leading Tier 1 supplier in Illinois, IEMA US designed and managed the migration of an obsolete automation infrastructure, turning an operational risk into a high-performance production asset.

Technical Challenge & Risk Assessment

The production site was operating on Rockwell SLC 500 and PLC-5 architectures, classified as End-of-Life (EOL). The technical analysis identified several systemic issues, including:

Operational Uncertainty: supply chain vulnerability due to the limited availability of spare parts for Step5 and SLC500 hardware.
Performance Gap: legacy motion control systems no longer able to meet the dynamic requirements of new OEM contracts.
Data Blindness: lack of modern communication protocols, resulting in the inability to monitor KPIs and optimize OEE.

Engineering Solution & Deployment

IEMA US implemented an integrated modernization strategy to ensure operational continuity:

Control Upgrade: migration to Rockwell Automation ControlLogix platforms, enabling IIoT-ready architectures and real-time communications.
Motion Optimization: reprogramming and synchronization of axes to reduce cycle times, resolving inefficiencies in the previous software logic.
HMI/SCADA Ecosystem: development of advanced interfaces for data tracking and predictive diagnostics.
Compliance: full compliance with UL standards, ensuring the safety and integration requirements necessary for the U.S. market.

Performance Results (ROI)

IEMA US’s engineering-driven approach delivered measurable improvements in plant performance:

+12% OEE: achieved through process stabilization and data visibility.
–15% Cycle Time: throughput optimization enabled by the new control architecture.
Risk Mitigation: resolution of hardware obsolescence issues and securing the production line.