Category: Manufacturing

VEC Technology

Greenville, PA / Little Falls, MN, United States

Boat Mold and Construction at a VEC Production Facility

Challenges

  • Multiple system complexity - Needed to integrate 8 Modicon PLCs, 5 Delta RMC controllers, and ~1,200 tags per station across two locations
  • Staff resource strain - Had 8 employees maintaining multiple disparate systems, creating operational inefficiencies
  • Future-proof requirements - Required 64-bit HMI/SCADA with 3D CAD visualization, web access, and SQL Server integration

Results

  • Operational efficiency - Reduced maintenance staff from 8 employees down to just 2 employees for the unified system
  • Enhanced visualization - Achieved "spectacular" 3D graphics with superb resolution, fully utilizing existing CAD investments
  • System consolidation - Single database for data logging, eliminated numerous custom VBA scripts via BridgeWorX integration

“GENESIS gave us unparalleled flexibility for creating the content we needed. We just plugged [it] onto our system to communicate with all our existing hardware interface drivers and software. With its GraphWorX tool, our HMI visualizations are much more intuitive and it was easy to do it myself.”

— Greg Telesz, Director of Engineering | VEC Technology, LLC

About VEC Technology

VEC Technology’s Greenville, PA, location provided custom composite manufacturing. Its then-parent company, J&D Acquisitions, also owned Larson Boats, a Little Falls, MN, manufacturer of recreational boat hulls that utilized the VEC process.

This process was described as “a patented, state-of-the-art, computer-controlled manufacturing process that guarantees that every part was made to the most exacting standards of fit and finish, resulting in parts with unparalleled beauty and unprecedented quality.”

VEC Technology considered itself a one-stop shop for OEMs, providing:

  • Part concepts
  • Design
  • Engineering
  • Tooling
  • Manufacturing

The Pennsylvania facility included seven molding stations. The company stated that manufacturing cells using its patented Floating Mold technology delivered “low-cost, high-quality, extremely accurate, closed-mold solutions.”

VEC Technology reported achieving “great success” in the following markets:

  • Marine
  • Construction
  • Containers
  • Transportation
  • Farming equipment
  • Recreational vehicles

Larson Boats, itself a customer of VEC Technology, could process boat hulls in the 17–24 ft range at its Minnesota location, which included eight molding stations and an automation mix plant.

“GENESIS gave us unparalleled flexibility for creating the content we needed. We just plugged [it] onto our system to communicate with all our existing hardware interface drivers and software. With its GraphWorX tool, our HMI visualizations are much more intuitive and it was easy to do it myself.”

— Greg Telesz, Director of Engineering | VEC Technology, LLC
A 3D Rendering of a Boat During Construction Visualized Through GENESIS64/GraphWorX64 A 3D Rendering of a Boat During Construction Visualized Through GENESIS64/GraphWorX64

Software Deployed

VEC Technology selected:

  • GENESIS64™ 64-bit HMI/SCADA software
  • BridgeWorX™ (real-time workflow for data bridging)
  • ReportWorX™ (enterprise reporting, charting and analysis)
  • OPC Server (supporting both OPC-UA and OPC-DA connectivity)
  • WebHMI (Web-based, real-time visualization)
A 3D Rendering of a Boat During Construction Visualized Through GENESIS64/GraphWorX64 A 3D Rendering of a Boat During Construction Visualized Through GENESIS64/GraphWorX64
A VEC Technology Fluid Transfer Control Screen A VEC Technology Fluid Transfer Control Screen

Project Summary

VEC Technology required an HMI/SCADA solution with data bridging, reporting, and archiving capabilities. The system needed to operate over the Web, integrate with the OPC communications protocol, and interface directly with the company’s product databases.

The solution would control and monitor VEC Technology’s patented closed molding operations and manage parameters based on several criteria, including:

  • Product type
  • Ambient conditions
  • Material properties

In addition, the company required long-term storage of multiple key parameters to support product warranty information. VEC Technology sought future-proof technology that could:

  • Present a simple user interface for making edits
  • Provide an easily maintained Web-based client/server architecture

The company also aimed for a “single vendor” approach to reduce both the number of automation interfaces and the extra support staff needed to maintain multiple systems.

The engineering team allowed a 10-month development cycle for the first installation, ensuring in-house personnel would gain familiarity with the selected HMI/SCADA solution. The software needed to interface with multiple systems and hardware, including:

  • Eight Modicon PLCs across two locations
  • Five Delta RMC controllers
  • Temperature, pressure, and proximity gauges
  • Scales and valves

Each molding station required the HMI/SCADA software to handle approximately 1,200 tags.

For this project, VEC Technology maintained four servers and 16 client stations. The company also used several Microsoft applications, including:

  • Microsoft Office
  • Microsoft Access (to modify process input parameters)
  • Microsoft SQL Server (for long-term historical data storage)

Two competitor solutions were considered, along with the option of keeping existing software from other providers. Ultimately, VEC Technology chose Mitsubishi Electric Iconics Digital Solutions.

A VEC Technology Fluid Transfer Control Screen A VEC Technology Fluid Transfer Control Screen
Injection Control Screen Injection Control Screen

Benefits of the System

VEC Technology wanted a single-source HMI/SCADA program that would:

  • Require minimal custom scripting and programming
  • Run optimally on 64-bit operating systems
  • Easily handle 3D visualization to fully utilize existing CAD data of equipment

Additionally, the company required software that could:

  • Read and write natively to Microsoft SQL Server
  • Support global aliasing to minimize development time and costs

GENESIS64 now provides what VEC Technology describes as “spectacular” and “rich” 3D graphics with “superb resolution” and an enhanced operator experience, fully leveraging the company’s CAD investments. The company now uses a single database for data logging, while GENESIS BridgeWorX software has eliminated numerous custom VBA scripts.

As a result, VEC Technology reduced its operational staff needs—from eight employees tasked with maintaining multiple systems to just two employees maintaining the new unified system.

Looking ahead, the company plans to expand its GENESIS-integrated application by implementing downstream post-molding stations to input quality data directly into databases, eliminating the need for paper forms.

Injection Control Screen Injection Control Screen
An Operator Monitoring Hull Production An Operator Monitoring Hull Production

Conclusion

VEC Technology and Larson Boats required an HMI/SCADA solution that would allow them to continue delivering customized options for their own customers while improving efficiency and reliability. The GENESIS64 HMI/SCADA suite, with its wide range of integrated manufacturing intelligence tools, proved to be the ideal fit—tailored to their unique processes and scalable to support evolving requirements.

By consolidating systems, streamlining operations, and enhancing visualization, GENESIS64 has positioned VEC Technology and Larson Boats to deliver higher-quality products, reduce operational complexity, and maintain a competitive edge well into the future.

An Operator Monitoring Hull Production An Operator Monitoring Hull Production

Case Study Details

  • HMI/SCADA Solution
  • OPC Server
  • 1,200 Tags per Molding Station
  • 3D Visualization for CAD Data