{"id":620,"date":"2026-06-29T10:28:45","date_gmt":"2026-06-29T15:28:45","guid":{"rendered":"https:\/\/kasacontrols.com\/blog\/?p=620"},"modified":"2026-06-29T10:28:47","modified_gmt":"2026-06-29T15:28:47","slug":"transforming-the-shop-floor-with-scada","status":"publish","type":"post","link":"https:\/\/kasacontrols.com\/blog\/2026\/06\/29\/transforming-the-shop-floor-with-scada\/","title":{"rendered":"Transforming the Shop Floor with SCADA"},"content":{"rendered":"\n<p><strong>Kasa Controls &amp; Automation + Prince Hydraulics<\/strong><\/p>\n\n\n\n<p>In today\u2019s fast-paced manufacturing environment, access to the right information\u2014at the right time\u2014can 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.<\/p>\n\n\n\n<p>Partnering with Kasa Controls &amp; Automation, Prince Hydraulics implemented a powerful SCADA-driven solution that unified information, simplified workflows, and dramatically improved efficiency.<\/p>\n\n\n\n<p>If you would like to watch a short video about this System, click here: <a href=\"https:\/\/www.youtube.com\/watch?v=MOTWI5te9CA\">Transforming Shop Floor Efficiency with the Prince SCADA System &#8211; YouTube<\/a>.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>The Challenge: Too Much Time Spent Searching for Information<\/strong><\/p>\n\n\n\n<p>Before the implementation, operators at Prince Hydraulics faced a common but costly obstacle\u2014fragmented data.<\/p>\n\n\n\n<p>To perform a single task, employees often had to:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Navigate between multiple systems and file locations<\/li>\n\n\n\n<li>Manually locate programs, blueprints, and inspection requirements<\/li>\n\n\n\n<li>Piece together the information needed for each job<\/li>\n<\/ul>\n\n\n\n<p>This process consumed valuable production time and increased the risk of errors.<\/p>\n\n\n\n<p>Prince\u2019s Yankton SD General Manager, Colin Kathol, explains:<\/p>\n\n\n\n<p>\u201cYou had to go to this icon\u2026to that file folder\u2026just a lot of time spent trying to gather the right information.\u201d<\/p>\n\n\n\n<p>The issue wasn\u2019t a lack of data\u2014it 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.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>The Solution: A Unified SCADA System Built Around the Operator<\/strong><\/p>\n\n\n\n<p>Kasa Controls &amp; 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.<\/p>\n\n\n\n<p><strong>Key capabilities of the system included:<\/strong><\/p>\n\n\n\n<p><strong>1. Model-Based Data Delivery<\/strong><br>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.<\/p>\n\n\n\n<p><strong>2. Single-Screen Operator Interface<\/strong><br>Operators can now access:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Machine programs<\/li>\n\n\n\n<li>Inspection operation sheets<\/li>\n\n\n\n<li>Engineering blueprints<\/li>\n\n\n\n<li>Work instructions<\/li>\n<\/ul>\n\n\n\n<p>\u2014all from the various system screens available at each process step, and focused on that step.<\/p>\n\n\n\n<p><strong>3. Automated Workflow Prompts<\/strong><br>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.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>The Impact: Faster Setup, Smarter Operations<\/strong><\/p>\n\n\n\n<p>The results were immediate and measurable.<\/p>\n\n\n\n<p><strong>Reduced Setup Times<\/strong><\/p>\n\n\n\n<p>By eliminating manual searching and setup steps, operators can transition between jobs significantly faster.<\/p>\n\n\n\n<p>\u201cWhat it really helped us\u2026is speed up our setup times.\u201d<\/p>\n\n\n\n<p><strong>Improved Shop Floor Visibility<\/strong><\/p>\n\n\n\n<p>The system provides a clear visual overview of:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>What work is being done<\/li>\n\n\n\n<li>When it\u2019s happening<\/li>\n\n\n\n<li>Where production stands<\/li>\n<\/ul>\n\n\n\n<p>This level of insight allows for better planning and decision-making in real time.<\/p>\n\n\n\n<p><strong>Centralized Data from Across the Business<\/strong><\/p>\n\n\n\n<p>Kasa helped Prince Hydraulics \u201cmine\u201d data from multiple sources\u2014including engineering servers and ERP systems\u2014and consolidate it into one accessible platform.<\/p>\n\n\n\n<p>This aligns with Kasa\u2019s 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.<\/p>\n\n\n\n<p><strong>Empowered Employees<\/strong><\/p>\n\n\n\n<p>Most importantly, the system was designed with the operator in mind. According to Lonnie Folkers, Plant Shop Foreman:<\/p>\n\n\n\n<p>\u201cFor me, it was all about the people on the shop floor\u2026giving them what they need to be successful.\u201d<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>Beyond Conveyors: Adding the \u201cBrains\u201d to the Operation<\/strong><\/p>\n\n\n\n<p>A production line can move parts from point A to point B\u2014but without intelligent control, it lacks the agility and intelligence modern manufacturing demands.<\/p>\n\n\n\n<p>This project demonstrates how SCADA acts as the <strong>\u201cbrains of the operation\u201d<\/strong>, delivering:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Real-time decision support<\/li>\n\n\n\n<li>Seamless communication between systems<\/li>\n\n\n\n<li>Data-driven production control<\/li>\n\n\n\n<li>Integration with each process step equipment<\/li>\n<\/ul>\n\n\n\n<p>Kasa Controls &amp; 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.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>A True Partnership: Listening First, Engineering Second<\/strong><\/p>\n\n\n\n<p>One of the most impactful aspects of this project wasn\u2019t just the technology\u2014it was the collaboration.<\/p>\n\n\n\n<p>\u201cYou guys are great listeners\u2026on the same exact page as us.\u201d <strong>Colin Kathol.<\/strong><\/p>\n\n\n\n<p>Prince Hydraulics had been searching for a solution since 2011 that could unify their data and streamline operations. With Kasa\u2019s help, they finally achieved that vision.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>Ready to Modernize Your Operation?<\/strong><\/p>\n\n\n\n<p>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.<\/p>\n\n\n\n<p>Kasa Controls &amp; Automation brings decades of expertise in:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>SCADA system design<\/li>\n\n\n\n<li>PLC and HMI programming<\/li>\n\n\n\n<li>Data integration and ERP connectivity<\/li>\n\n\n\n<li>Turnkey conveyor automation systems<\/li>\n<\/ul>\n\n\n\n<p>to help you build smarter, more efficient operations from the ground up.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>Learn more at kasacontrols.com or connect with our team to start your automation journey today.<\/strong><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Kasa Controls &amp; Automation + Prince Hydraulics In today\u2019s fast-paced manufacturing environment, access to the right information\u2014at the right time\u2014can 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&#8230;<\/p>\n","protected":false},"author":10,"featured_media":621,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[53],"tags":[173,52,170,172,169,168,171,167],"class_list":["post-620","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-system-integration","tag-ignition-software","tag-industrial-automation","tag-industrial-controls-and-automation","tag-kasa-controls","tag-plant-equipment-integration","tag-plant-floor-data","tag-prince-hydraulics","tag-scada"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.1.1 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Transforming the Shop Floor with SCADA - Kasa Controls Blog<\/title>\n<meta name=\"description\" content=\"Learn 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