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IoT and Smart Manufacturing

Smart Manufacturing

The fourth industrial revolution has been referred to as “Smart Manufacturing”, or “Industry 4.0”, but, what does this really mean?

Simply put, Smart Manufacturing is based on a combination of digital and physical systems that blend communications, IT, data, device, equipment and people. These systems transform traditional plants into smart factories through highly intelligent connected systems that create a fully digital supply chain. The value of a digital supply chain lies in its volume of rich, correlated data, which allows you to recognize and optimally respond to events in real-time, and provides a treasure trove of data to be mined and analyzed to support continuous improvement efforts. And, the digital supply chain is more agile than traditional supply chains, able to keep up with the pace of operational change in today’s manufacturing environment.

If you’re thinking that this sounds a lot like the “Manufacturing Intelligence” or “Operational Intelligence” terms that have become common over the last few years, you’d be right. But, there is one fundamental difference between then and now. The Internet of Things (IoT).

Traditional manufacturing systems (ERP, MES, dashboards) suffer from two design limitations that make them ill-suited to support Smart Manufacturing. One, they do not do a good job of supporting the disparate data types (transactional operational and product quality data; time-series series process data, and unstructured information) that must be correlated in order to support rapid analysis and decision-making that is needed to improve performance. Two, traditional development tools impose a design-develop-deploy life cycle that inhibits the agile, rapid development life cycle that is needed so the systems and data that support people and processes can evolve as quickly as the business.

IoT platforms promise to change this.


Fundamentally, the Internet of Things (IoT) is the networked connection of people, processes, data, and things (machines, devices, sensors, products, etc.).

With a large amount of available data, smart equipment, and the need for real-time data, manufacturing operations are a natural fit for IoT technology. Manufacturers can leverage the IoT to create solutions that transform production operations and improve performance by providing real-time visibility, execution, and collaboration across people, systems, and assets. This visibility and collaboration drives operational excellence through business efficiency and cost reduction.

Sustainable competitive advantage comes from having the right strategic positioning combined with operational effectiveness. The essence of operational effectiveness is to continuously improve all functions and processes related to manufacturing operations. IoT platforms provide new abilities to drive operational effectiveness that can be quickly and cost-effectively implemented without significant disruption to existing operations and systems, resulting in a rapid time to benefit.


Callisto, IoT, and Smart Manufacturing

Callisto Integration has over 25 years of experience in bringing technology solutions to the manufacturing sector. With thousands of solutions deployed to Food & Beverage, CPG, Automotive, Metals, Specialty Chemical, and other manufacturing verticals, we have a deep understanding of manufacturing operations and related business processes.

Our consulting practice helps manufacturers assess their operations to determine how best to leverage IoT technologies, in conjunction with their existing systems, to eliminate the silos that slow down responses and impede agility.

With our history in developing MES and control systems, we have a deep understanding of ERP, PLM, MES, and other shop floor systems you need to connect to in order to achieve the vision of smart, connected operations. Our agile development methodologies supporting rapid prototyping and iterative development, resulting in shorter time to benefit. Our automation and controls groups has years of experience connecting to shop floor equipment and devices, a key element of IoT.

In short, Callisto has the experience and knowledge required to bring the value of IoT to the manufacturing sector.


Manufacturing Execution Systems (MES)

Callisto delivers information required by factory personnel to effectively manage the manufacturing process from order launch to the production of finished goods. Using current and accurate data, the MES guides, initiates, responds to, and reports on plant activities as they occur.

Key capabilities of a MES and the associated business benefits include:

Product Tracking

High product mix, small order quantities and short lead times all create a complex tracking environment. Having an accurate understanding of the current status of production orders helps keep customer service levels high, provides the information required to minimize WIP and inventory levels, and provides the ERP with accurate information, allowing for better production planning.

Quality Management

Knowing your products have been made to the correct quality specifications before they are shipped is of critical importance. An MES can monitor product and process characteristics in real-time, notifying plant personnel as soon as deviations are detected. Using its Product Genealogy capabilities, the MES can rapidly determine the scope of the quality deviation, and quarantine production to ensure none of the suspect product is shipped. In addition to its real-time capabilities, the MES captures historical quality information, providing detailed information to support on-going quality improvement initiatives.

Product Genealogy

When quality problems do occur, having a detailed and accurate understanding of the scope of the problem is key to containing and managing the issue. With product genealogy, the MES tracks which products were made on which pieces of equipment; which materials were used in which batches of product; and which personnel were involved. Once the product defect is traced back to its root cause, be it off-spec materials, a process deviation, or incorrect procedures, the MES will identify all suspect production that could have been impacted, allowing you to rapidly contain the issue with a high degree of confidence.

ERP and MES Integration

Our teams are also practiced in the use of information provided by ERP and MES systems to ensure that the equipment is set up correctly and is running to specification, thereby ensuring good first-pass product quality.

Controls Engineering

As a Controls System integration firm Callisto offers full integration services for PLC, DCS, and SCADA applications including requirements, design, development, testing, commissioning and training. In addition we offer panel and field wiring design.

SCADA Systems

Our Controls Engineering Team offers a deep knowledge of a wide variety of control and SCADA systems from major vendors such as Wonderware, GE Fanuc, Rockwell, Modicon, ABB and Siemens. We have developed our expertise in widely used applications such as batch, discrete and continuous control as well as our knowledge of industry specific processes.

Industry specific teams

Our teams focus on the technologies and solutions that are required by our customers in key industries such as Automotive, CPG, Food & Beverage, Pharmaceutical, Metals and Power Generation. This allows our employees to narrow their focus to provide our clients with a greater depth of expertise and industry-specific knowledge.

Controls Engineering Team

As a broadly focused systems integration firm, Callisto's Controls Engineering Team understands the data requirements of higher level systems and how to most effectively use control systems to automatically capture this data, reducing the need for time consuming and error prone manual data collection.

Manufacturing Consulting

Callisto consulting services help clients achieve maximum output from their existing manufacturing resources. We help our customers identify opportunities for improvement and make the technology and organizational changes required to realize those improvements.

Key areas of practice include:

Systems Roadmap Development

- Callisto works with your business and IT personnel to assess the gap between your current manufacturing systems functionality and the capabilities required to support your company's strategic manufacturing initiatives. Our consultants develop a plan to migrate to the desired architecture and functionality, and work with you to develop the business case for the migration.

Program Management

- Breaking a major systems implementation effort into a series of smaller, self-contained, yet complimentary projects helps manage the cost and schedule risks often encountered in large IT projects. Our program managers work with you to develop the initial program plan, and then provide program management services over the course of the program. Program management services include organizational change management, to ensure your personnel adapt to the changes through the correct training and support; coordination of internal resources; coordination of the individual projects under the program to ensure the projects are complimentary and working together to achieve program goals; and periodic reassessment of the program plan to account for changes in business priorities and conditions.

Performance Improvement

Our consultants assess your current manufacturing performance against desired levels to determine the problems that are preventing your facilities from achieving its targets. Typical solutions involve the implementation of an OEE (Overall Equipment Effectiveness) system to capture and monitor performance data in real-time, and organizational change management to ensure this information is used effectively to drive continuous improvement. Manufacturing Business Process Design Callisto assists you in developing work and data flows to ensure your manufacturing practices are streamlined and cost effective. Based on international standards such as the SCOR (Supply Chain Operations Reference) model and ISA-95, our consultants will model the business processes needed inside the factory, which then become the basis for the functional requirements for the MES.

Callisto Integration
Albany, OR: 541-924-1741
Richmond, VA: 804-212-3013
Toronto, ON: 905-339-0059
Warwick, UK: +44 1926 62 3400
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