Design in Systems: McCain Internship

Roles

Industrial Systems Analyst, SCADA UX Evaluator, Design Researcher

Internship Report, SCADA & ML Integration Proposal, Signage & HMI Compliance Study, R&D Packaging Observations

Notion, FactoryTalk SE, Figma, Excel, IR Thermometer, ISO 7010 Guidelines

Insights from a 15-day in-plant design analysis of safety, signage, and SCADA systems.

McCain Internship Report captures a 15-day observational deep dive into industrial food manufacturing at McCain Foods India. The project examined production workflows, SCADA system limitations, signage compliance, and proposed advanced integrations including AI diagnostics and V2X safety protocols.

Research Scope

The internship aimed to bridge design thinking with industrial automation. It spanned analysis of:

End-to-end potato processing: from raw intake to frozen dispatch.
Supervisory Control and Data Acquisition (SCADA) system gaps.
Human–machine interaction ergonomics and safety standards.
AI/ML potential for predictive diagnostics.
RFID+V2X communication for collision prevention and evacuation tracking.

Key Research Axes

SCADA System Enhancement
- Identified high manual load in trend analysis.
- Proposed AI-based anomaly detection, root-cause mapping, and preventive maintenance workflows.
- Designed a plug-in pipeline leveraging edge computing and FactoryTalk SE APIs.
Visual Communication & Safety
- Audited ISO 7010/3864 signage adherence.
- Found non-compliant exits and faded floor markings.
- Suggested font-size changes in HMI and UI tree flattening for faster operator navigation.
Factory Layout & Flow Efficiency
- Applied the Seven Flow framework.
- Proposed spatial redesigns for pedestrian-forklift zones.
- Recommended visual overlays and heatmaps via SCADA integrations.
V2X Integration
- Real-time tracking of forklifts and personnel.
- Automated proximity alerts, emergency roll-call, and dispatch optimization.
- Proposed modular rollout using UWB tags and SCADA overlay dashboards.
R&D: MATS Packaging
- Observed trials of Microwave-Assisted Thermal Sterilization.
- Noted superior vacuum retention and texture vs retort methods.
- Outlined integration limitations and scope for premium SKUs.

Outcomes

The report includes actionable recommendations spanning automation, layout, safety, and data intelligence. It showcases the role of design researchers in system-level optimization—where ergonomics, safety, and machine data intersect to improve productivity and worker well-being.