Kasa Controls & Automation + Prince Hydraulics

In today’s fast-paced manufacturing environment, access to the right information—at the right time—can make or break productivity. For Prince Hydraulics, a leading manufacturer of hydraulic cylinders, valves, and pumps, the challenge was clear: critical production data was scattered across multiple systems, slowing operators down and creating unnecessary complexity on the shop floor.

Partnering with Kasa Controls & Automation, Prince Hydraulics implemented a powerful SCADA-driven solution that unified information, simplified workflows, and dramatically improved efficiency.

If you would like to watch a short video about this System, click here: Transforming Shop Floor Efficiency with the Prince SCADA System – YouTube.

The Challenge: Too Much Time Spent Searching for Information

Before the implementation, operators at Prince Hydraulics faced a common but costly obstacle—fragmented data.

To perform a single task, employees often had to:

  • Navigate between multiple systems and file locations
  • Manually locate programs, blueprints, and inspection requirements
  • Piece together the information needed for each job

This process consumed valuable production time and increased the risk of errors.

Prince’s Yankton SD General Manager, Colin Kathol, explains:

“You had to go to this icon…to that file folder…just a lot of time spent trying to gather the right information.”

The issue wasn’t a lack of data—it was a lack of accessibility and integration. Plus, errors caused by accessing the wrong part data tended to be repeated for a whole batch of parts, causing those parts to be scrapped and started over from scratch.

The Solution: A Unified SCADA System Built Around the Operator

Kasa Controls & Automation specializes in integrating operational technology (OT) with information technology (IT), centralizing plant floor data into a single, actionable system. For Prince Hydraulics, that meant designing a SCADA solution that brought everything together in one place.

Key capabilities of the system included:

1. Model-Based Data Delivery
Kasa engineered the system to tie production data directly to specific product model numbers. As a product moves down the power and free conveyor line, the system automatically recognizes it and pulls all associated information for each specific fabrication process.

2. Single-Screen Operator Interface
Operators can now access:

  • Machine programs
  • Inspection operation sheets
  • Engineering blueprints
  • Work instructions

—all from the various system screens available at each process step, and focused on that step.

3. Automated Workflow Prompts
Instead of searching for files, operators are prompted automatically with exactly what they need based on the job in front of them. What to weld and where, settings for the automatic skeeving machine, final automatic weld sealing details, etc. Plus, automatic processes, including several wash steps between processes, are also controlled along with the movement of carriers via the power and free conveyor.

The Impact: Faster Setup, Smarter Operations

The results were immediate and measurable.

Reduced Setup Times

By eliminating manual searching and setup steps, operators can transition between jobs significantly faster.

“What it really helped us…is speed up our setup times.”

Improved Shop Floor Visibility

The system provides a clear visual overview of:

  • What work is being done
  • When it’s happening
  • Where production stands

This level of insight allows for better planning and decision-making in real time.

Centralized Data from Across the Business

Kasa helped Prince Hydraulics “mine” data from multiple sources—including engineering servers and ERP systems—and consolidate it into one accessible platform.

This aligns with Kasa’s broader capability to gather and store plant floor data from PLCs, machines, and enterprise systems into a unified database. System views are available at each process step and via server access to management offices.

Empowered Employees

Most importantly, the system was designed with the operator in mind. According to Lonnie Folkers, Plant Shop Foreman:

“For me, it was all about the people on the shop floor…giving them what they need to be successful.”

Beyond Conveyors: Adding the “Brains” to the Operation

A production line can move parts from point A to point B—but without intelligent control, it lacks the agility and intelligence modern manufacturing demands.

This project demonstrates how SCADA acts as the “brains of the operation”, delivering:

  • Real-time decision support
  • Seamless communication between systems
  • Data-driven production control
  • Integration with each process step equipment

Kasa Controls & Automation has been delivering these types of turnkey industrial automation solutions since 1974, completing more than 10,000 projects across industries requiring reliable, high-performance systems.

A True Partnership: Listening First, Engineering Second

One of the most impactful aspects of this project wasn’t just the technology—it was the collaboration.

“You guys are great listeners…on the same exact page as us.” Colin Kathol.

Prince Hydraulics had been searching for a solution since 2011 that could unify their data and streamline operations. With Kasa’s help, they finally achieved that vision.

Ready to Modernize Your Operation?

If your team is still navigating multiple systems, chasing down files, or struggling with visibility on the shop floor, it may be time to rethink your approach.

Kasa Controls & Automation brings decades of expertise in:

  • SCADA system design
  • PLC and HMI programming
  • Data integration and ERP connectivity
  • Turnkey conveyor automation systems

to help you build smarter, more efficient operations from the ground up.

Learn more at kasacontrols.com or connect with our team to start your automation journey today.