Work: Ethernet Retrofit
The goal was to have a system that could accurately track production numbers, downtime, cycle time, faults, and any other data required for management.
The programmable logic controllers in the plant were extremely ancient Toyopuc (Toyoda) and Mitsubishi's Q series. Each system was unique from both a hardware and software point of view, several controllers required expansions as there wasn't any I/O available.
See the above diagram for an overview of the final setup.