Principal investigator: Joseph M. Mahoney
University: Alvernia University
Industry partner: Brentwood Industries
This project advances Brentwood Industries’ digital manufacturing transformation by developing a data‑driven controls optimization and alarm management strategy enabled by their newly deployed manufacturing execution system. Two Alvernia electrical engineering students, supported by a graduate assistant, will analyze high‑resolution MES event data, historical alarm logs, and operational context to evaluate and refine thresholds for programmable logic controller alarms and configurations on selected production assets. Through structured alarm rationalization, controls tuning, and pilot validation, the project will reduce nuisance alarms, improve equipment reliability, and enhance operational stability. The methodology integrates MES analytics with PLC programming, creating a scalable digital framework that Brentwood can extend across multiple lines and facilities. Beyond operational benefits, the project strengthens Pennsylvania’s manufacturing talent pipeline by providing hands-on experiential learning in automation, controls, and data analytics, capabilities that directly support the commonwealth’s workforce and competitiveness goals.