Discover how leading industrial companies leverage Software Toolbox connectivity solutions to transform their operations, improve efficiency, and drive innovation.
California Resources Co faced critical challenges in connecting their legacy SCADA systems across multiple oil fields in the San Joaquin Basin. With over 5,000 wells and aging PLCs from various manufacturers, they needed a unified connectivity solution. TOP Server's extensive driver library enabled seamless communication between legacy Allen-Bradley, Modicon, and Siemens controllers and their modern data historians. The implementation reduced data latency by 70% and enabled real-time production optimization across all facilities.
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Operating oil and gas facilities across remote locations in Colombia presented unique connectivity challenges for SierraCol Energy. The company needed to transport real-time production data from field PLCs to their cloud-based analytics platform while maintaining security and reliability. Using Cogent DataHub in conjunction with TOP Server, they established secure, encrypted data pipelines from over 30 remote sites to AWS. This solution enabled centralized monitoring and reduced field visit requirements by 45%, significantly lowering operational costs.
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Dow Chemical's Freeport, Texas facility operates multiple chemical production lines with DCS systems from Honeywell, Yokogawa, and Emerson. The challenge was aggregating process data from these disparate systems into a centralized analytics platform for real-time process optimization. TOP Server provided native connectivity to all three DCS platforms, enabling seamless data integration. Combined with professional services for custom driver configuration, Dow achieved 99.8% data availability and reduced batch cycle times by 12% through improved process insights.
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Subaru Indiana Automotive needed to integrate quality data from 120+ stations across three assembly lines, each running different generations of Fanuc and KUKA robotics controllers. The existing patchwork of custom interfaces created data gaps and maintenance nightmares. TOP Server's comprehensive driver support connected all robotic controllers, torque tools, and vision systems to their manufacturing execution system. The unified connectivity solution reduced integration costs by 60% compared to custom development and enabled real-time quality tracking, reducing defect rates by 23%.
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Moderna's rapid expansion of mRNA vaccine production facilities required robust, validated connectivity solutions that met FDA 21 CFR Part 11 requirements. With bioprocessing equipment from multiple vendors and strict data integrity requirements, they needed a connectivity platform that could provide audit trails and secure data transport. TOP Server with Mission Critical Support delivered validated OPC connectivity to bioreactors, filling lines, and environmental monitoring systems. The solution achieved 100% uptime during critical production runs and passed all FDA audit requirements for electronic records.
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Danone USA operates 12 dairy processing facilities across North America, each with unique PLCs, HMIs, and batch control systems installed over different decades. The corporate team lacked visibility into production metrics across sites, making it difficult to identify best practices and optimize operations. TOP Server connected Rockwell, Siemens, and Schneider Electric systems at all 12 sites, while Cogent DataHub aggregated data to a central cloud data lake. This infrastructure enabled corporate-wide production dashboards and resulted in a 15% improvement in overall equipment effectiveness (OEE).
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Corning's specialty glass manufacturing process requires precise temperature and pressure control across multiple furnaces and forming stations. Their quality control system needed millisecond-level data from PLCs controlling these critical parameters. Existing connectivity solutions introduced unacceptable latency and occasional data loss. TOP Server's optimized OPC DA and UA architecture provided sub-50ms response times while handling over 10,000 tags per furnace line. The improved data fidelity enabled tighter process control, reducing material waste by 8% and improving first-pass yield by 11%.
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