Component Manufacturing Line
Barcode + G160 Smart Upgrade

II. Core Pain Points

Manual parameter entry at HMI against work orders is the hidden source of yield fluctuation.

• Manual input, errors hard to avoid: 5-6 parameters per work order; workers key in one by one against the work order at the HMI. Fatigue, language and proficiency all introduce errors - "wrong line read, wrong position entered, item omitted" happen from time to time.
• Higher error rate and lower yield after relocation: After the line moved to Vietnam, Vietnamese workers performed the same manual-input flow, but the error rate rose, causing the final line yield to drop, directly affecting output and manufacturing cost.
• Errors found late, high cost: Wrong parameter entry is often exposed only at later-stage QC, by which time rework or scrap has occurred, and it is hard to accurately trace back to specific work order and shift, expanding losses.
• No permission and work-order closed loop: Manual input cannot associate "who operated, which work order, what parameters used" with MES; the process is untraceable, and problems can only be investigated afterwards.

III. Why Traditional Approaches Fail

Adding people, modifying PLC, replacing the whole line - all hard to balance "fast, low-risk, replicable".

• Adding review personnel, treats symptom not root: Adding another person to review input doubles labor cost but still relies on people; error rate cannot reach zero, and local labor after relocation is equally unstable.
• Modifying PLC / HMI programs, high risk and cycle: Directly changing PLC logic or HMI screens requires coordinating the equipment vendor, long cycle, high cost, and may disturb the existing mature process; the customer is unwilling to take this risk.
• Whole-line automation retrofit, high capital expenditure: Unrealistic for a customer who "has relocated and seeks quick relief" - large investment, long downtime, far water cannot save near fire.

IV. Solution: Scanner + AIS-G160

Replace "manual key-in" with "scan validation + automatic PLC parameter write"; workers switch from input to verification.

• Add 1D barcode scanner + AIS-G160: Install a 1D barcode scanner next to the PLC-controlled equipment; the scanner connects to G160 via serial (RS232); G160 connects to MES via Ethernet, undertaking edge-side protocol conversion and data forwarding.
• Scan to report (identity & permission validation): When starting work, the worker first scans their ID barcode with the scanner; the scanner reads it and passes it to G160 via serial; G160 reports to MES, which confirms the worker's report and operation permission, preventing unauthorized operation.
• Scan work order (work-order validation): The worker then scans the 1D barcode on the work order; the scanner reads it and passes it to G160; G160 reports to MES, which confirms the work-order number and corresponding process parameters, binding this operation.
• MES issues parameters -> G160 writes PLC: MES issues the work order's process parameters to G160; G160 directly writes them to the corresponding PLC register addresses; parameters are displayed on the HMI in real time - no manual key-in throughout.
• Worker verifies and executes: The worker sees the written parameters on the HMI and compares them with the work order; after confirmation, executes. Workers only "verify", no longer "input" - input errors are eliminated at the source.

VI. Why AIS-G160

The three capabilities "serial in, Ethernet out, register write" exactly match all demands of the scan-input retrofit.

• Serial + Ethernet dual interface: The 1D barcode scanner comes in via serial, MES goes out via Ethernet; G160 performs protocol conversion and forwarding at the edge; on-site wiring is simple, plug-and-play.
• Direct PLC register write: Writes parameters to the corresponding PLC register addresses, real-time to HMI, without modifying the PLC original program and HMI screens - low retrofit risk, fast results.
• Complete protocols: Built-in 500+ industrial protocols covering mainstream PLC (Siemens, Mitsubishi, OMRON, Delta, Inovance, etc.); the PLC-controlled equipment in this case is connected out-of-the-box, no per-brand development.
• Add-on, replicable: Without touching the original process logic, new bases after relocation only need to deploy the same "scanner + G160" and link MES to replicate; low capital expenditure, short deployment cycle.

VII. FAQ

High-frequency questions about "scanner + G160 replacing manual HMI input".

VIII. PLC Brands & Models Supported by G160

This case centers on G160 acquiring multi-brand PLC. AIS-G160 has a built-in library of 500+ industrial device protocol drivers. The following are mainstream PLC brands and models verified for data acquisition (some models require on-site interface confirmation), serving as a basis for solution selection and field verification.