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Full T&T and SCADA Line Integration at FAT Locations

CYBERLYNK > Case Study > Full T&T and SCADA Line Integration at FAT Locations
CYBERLYNK Case Study B

About Project

CYBERLYNK enabled full remote Track & Trace and SCADA integration across multiple vendor FAT locations in Ireland and Germany. By testing end-to-end line behaviour earlier in the project, critical integration issues were identified and resolved before delivery, accelerating production readiness by 7.5 weeks.

The Challenge

Complex pharmaceutical production lines are often assembled across multiple vendor locations, with Track & Trace and SCADA integration traditionally deferred until Site Acceptance Testing (SAT). This fragmented approach limits visibility of end-to-end system behaviour and increases the risk of late-stage integration failures.

Project Info

  • Client:

    Pharma Manufacturer

  • Project Stage:

    Factory Acceptance Testing (FAT)

  • Locations:

    Ireland (2 locations) ↔ Germany

  • CYBERLYNK Role:

    Multi-site Pre-SAT integration

The CYBERLYNK Approach

CYBERLYNK securely connected the customer’s Track & Trace (L3) offline system with the Start of Line at a vendor FAT site in Ireland and the End of Line at a separate vendor FAT site in Germany. This enabled full remote integration testing of SCADA and Track & Trace workflows across geographically distributed equipment before system delivery.

Remote Integration Testing Performed
  • SCADA network integration enabling real-time batch start across all machines
  • Centralised SCADA audit trail recording from all machines to a database in Germany
  • L3 ⇔ L2 process order and serial number provisioning
  • Pallet-by-pallet aggregation data transfer during live batch execution*
  • Batch-end aggregation and unused serial number reconciliation

*During remote integration testing, a Track & Trace serialisation issue was identified with pallet-by-pallet data upload during batch execution. This issue was resolved by the vendor, followed by re-execution of the Track & Trace FAT, leading to full acceptance by the customer before delivery.

Outcomes & Business Impact
  • 7.5 weeks saved
  • Critical integration issues resolved at FAT rather than at customer site
  • Project significantly de-risked through early end-to-end integration testing
  • Engineering resources redeployed sooner to additional projects
  • Increased transparency into vendor readiness and system performance

Time Saved:

7.5 weeks