In the automotive industry, at Ford—one of the leading companies in the sector—the Pro4 IoT Platform and the BoQP Quality System application were developed and implemented to monitor quality control points, collect measurement data (via PLC, manual input, or Excel import), classify results as OK/NOK based on defined quality criteria, perform advanced SPC analyses on measurement data, generate various types of reports, and support periodic reporting functions.

This project also serves as an example of the modular architecture of the Pro4 IoT Platform, where a new application specific to the paint shop process was developed on the platform.

The existing BoQP application running on the Pro4 IoT Platform efficiently collects measurement data from multiple sources within production processes. In this context, data acquisition is performed through:

Manual operator inputs
Bulk data uploads via Excel
Automatic data reading from PLC systems

The collected data is evaluated by the system according to defined specifications, generating OK / NOT OK results. Users can generate reports based on this data, export outputs, and perform advanced BI analytics.

Since its establishment in 1958, Kayalar Copper Alloys Industry and Trade Inc. has become one of Turkey’s leading companies in the production of copper and copper alloy sheets, strips, coins, and token products, with a strong focus on technological advancement and high-quality standards.

Within the scope of the Production and Energy Monitoring Project, the Pro4 IoT Platform was successfully implemented to monitor and report energy consumption values as well as rolling, furnace, and continuous casting processes. This comprehensive solution aims to improve operational efficiency and facilitate data-driven decision-making processes.

Dashboard, HMI, and KPI Applications:
Users can monitor production and energy data in real time. Dashboards enable rapid evaluation of operational performance, while HMI (Human-Machine Interface) applications provide operators with more intuitive control. KPI applications allow tracking of targeted performance indicators.

Live and Historical Data Analytics:
The Pro4 IoT Platform provides access to both real-time and historical data, enabling users to evaluate process performance and make improvement-oriented decisions.

Periodic Reporting:
The system automatically generates reports at defined intervals, enabling management and technical teams to analyze production processes. These reports serve as an important resource for strategic decision-making.

Rule-Based Early Warning Alerts:
The system generates early warning alarms using logical queries to detect potential bottlenecks. These alerts enable operators to respond quickly and take corrective actions.

At KNAUF, one of the leading companies in the mining sector, all energy consumption values and weighing (scale) data across the entire production process, including production and social areas, are monitored through our Pro4 IoT Platform.

In addition to the Pro4 IoT Platform, an automation system consisting of Siemens PLCs, along with energy meters and scale data acquisition infrastructure, has been successfully installed by our technical team at KNAUF.

Dashboard, HMI, and KPI Applications:
Users can monitor production and energy data in real time. Dashboards enable rapid evaluation of operational performance, while HMI (Human-Machine Interface) applications provide operators with more intuitive control. KPI applications allow tracking of targeted performance indicators.

Live and Historical Data Analytics:
The Pro4 IoT Platform provides access to both real-time and historical data, enabling users to evaluate process performance and make improvement-driven decisions.

Periodic Reporting:
The system automatically generates reports at defined intervals, enabling management and technical teams to analyze production processes. These reports serve as a key resource for strategic decision-making.

Rule-Based Early Warning Alerts:
The system generates early warning alarms using logical queries to detect potential bottlenecks. These alerts enable operators to respond quickly and take corrective actions.

Data Acquisition Infrastructure:
The energy meter and weighing data acquisition infrastructure is critical for KNAUF’s energy management and production monitoring processes. It helps improve understanding and management of energy consumption.

Through this comprehensive system and technology integration, KNAUF optimizes its production processes, increases energy efficiency, and achieves operational excellence objectives.

At Beko Romania SA, operating under the Arctic brand in Romania, our home appliance production line modernization project has been successfully completed.

Scope of Work

The mechanical revision of the assembly and pre-heating conveyor line was carried out to improve operational efficiency.
System automation was implemented via the existing Omron PLC, optimizing control processes.
Electrical panels were revised to enhance system reliability and ensure compliance with current standards.
Cabling and on-site installation works were completed to ensure seamless connections across the production line.

At TOFAŞ, one of the leading companies in Turkey’s automotive industry, our Engine and Transmission Line project has been successfully completed.

Within the scope of the project, our mechanical partner Mimsan Conveyor carried out the installation of all conveyor systems, while PRO4 Technology provided the following services:

• Automation system on Siemens PLC
• Integration of drive and servo systems
• Power and control panels
• Installation and calibration of field sensors
• Cabling and on-site installation services

In this project, we delivered turnkey automation solutions, providing advanced technologies aimed at increasing efficiency, reducing downtime, and optimizing production processes in TOFAŞ’s manufacturing line. At PRO4 Technology, we are proud to have successfully delivered a project fully aligned with TOFAŞ’s needs through our experience in the automotive industry and our innovative engineering approach.

Kayalar Copper Alloys Industry and Trade Inc., founded in 1958, has become one of the leading companies in our country in the production of copper and copper alloy sheets, strips, coins, and token blanks, with a strong focus on technological advancement and quality.

At Kayalar Copper, within the scope of Cold Rolling ABB 800xA Automation System upgrades, HMI revision, integration of the ABB thickness measurement system with the AGC (Automatic Gauge Control) system, and production line data acquisition projects have been successfully completed.

Scope of Work and Completed Projects

ABB 800xA HMI Revisions:
The HMI system was upgraded to provide operators with a more intuitive and user-friendly interface for monitoring and controlling production processes. The new interface enhances operational visibility, enabling faster response to issues.

ABB Thickness Measurement System and AGC Integration:
The ABB thickness measurement system was integrated with the AGC (Automatic Gauge Control) system to ensure consistent thickness across all production lines. This integration enables real-time monitoring and automatic adjustments during the rolling process, improving product quality and minimizing material waste.

Production Data Acquisition Projects:
Data acquisition systems were implemented to collect real-time production data from various lines. These systems ensure seamless communication with the automation infrastructure and provide valuable insights for process optimization, enabling better decision-making and proactive maintenance.

A leading chemical plant and one of the key companies in the cement sector in Turkey is using our Augmented Reality (AR)-based Remote Support Application to provide maintenance and service support across its domestic and international facilities.

Augmented Reality-Based Remote Support Application:
The application enables technical teams to manage field operations quickly and effectively. Instead of sending an expert to the site, the approach focuses on bringing the operator’s working environment directly to the expert’s screen. With AR technology, experts can view on-site conditions in real time and resolve issues instantly.

Real-Time Problem Solving:
The remote support application helps operators identify and resolve equipment issues immediately. With AR assistance, experts can visually guide on-site personnel through complex processes, ensuring that operations are carried out correctly and efficiently. This approach effectively enables the expert to virtually join the field.

Training and Knowledge Sharing:
The application also makes a significant contribution to technical training. New employees are trained on-site by experienced experts through AR support, improving their understanding of complex processes. Augmented reality technology enables fast and effective transfer of expertise and know-how.

Performance and Efficiency Improvement:
With the AR-based remote support application, overall plant performance is improved, maintenance times are reduced, and production processes can be monitored more efficiently.

With an annual production capacity of 1.3 million tons of flat steel products and continuous investments aligned with its vertical integration strategy, Tezcan Galvaniz has successfully completed the integration of cold rolling process data with its ERP system.

Project Details

Cold Rolling Process Data Acquisition via OPC Server:
Process data from the cold rolling mill was collected through an OPC Server, ensuring seamless and reliable data communication between operational systems and business systems.

ERP System Integration:
The collected data was integrated into the ERP system, improving production planning, resource management, and reporting processes. This integration enables better decision-making through real-time production data.

Through this integration, Tezcan Galvaniz has taken a strong step forward in its digital transformation journey by improving operational efficiency. The seamless connection between the production line and ERP system has enhanced traceability, process transparency, and efficiency, supporting the company’s growth strategy.