How to Integrate Ignition SCADA with MES for End-to-End Visibility

Manufacturers using industrial automation software like Ignition by Inductive Automation are already ahead of the game–automating machines, managing PLCs, and building out HMIs. But many still struggle with a critical gap: the human side of production. Paper-based work instructions, disconnected operator input, and a lack of real-time traceability hinder performance and quality, especially in mixed manual and automated environments.

That’s where modern MES integration steps in. Combining a powerful HMI/SCADA platform like Ignition with a human-centric MES like PICO creates a system that captures, tracks, and reports both machine and human-driven processes–without writing custom code.

Why Ignition SCADA Alone Isn't Enough

Ignition is one of the most flexible HMI/SCADA software platforms available today. It excels at real-time control, visualization, and data acquisition from PLCs. But like most industrial automation software, its native data tracking and operator interaction tools aren’t designed for the complex traceability, validation, and compliance tasks that modern manufacturers increasingly need.

As a result, teams are left patching together solutions with spreadsheets, clipboards, or overly complex custom code to bridge the gap between machines and manual processes. This leads to:

• Incomplete traceability
• Missed compliance requirements
• High scrap and rework
• Loss of tribal knowledge

Ignition SCADA Integration with Pico MES: A Smarter Approach

Rather than replacing your existing SCADA system, PICO complements Ignition by integrating seamlessly to enhance its capabilities. This integration enables you to:

1. Capture and store data from PLCs and HMIs running on Ignition

2. Tie machine data to manual operations, including operator inputs, work instructions, and part validation

3. Visualize unified data with built-in BI tools and analytics dashboards (no custom reporting needed)

4. Track and trace parts across the full production line–from machine cycle to operator sign-off

With PICO, you don't need to build or maintain custom MES features in Ignition. You just connect and go.

Do Ignition SCADA and Pico MES Compete?

Not at all. In fact, Ignition and PICO are better together. Ignition focuses on machine automation and control. PICO adds the people layer–guidance, documentation, compliance, and manual process data capture.

This partnership is ideal for manufacturers that: 

☑️ Perform mostly manual assembly, but include automated machining or process control

☑️ Already have PLCs or SCADA systems, but aren’t collecting actionable data from their entire line

☑️ Need to unify disconnected systems without replacing existing HMI/SCADA software

👉 Listen as Steve Wishau, Head of Product at PICO, explains how the two systems work together to provide a complete view of production:

Here is a summary of how the two systems compare and contrast:

Why Ignition SCADA Users Need MES Integration

If you’re already running Ignition, it might be tempting to stretch its native capabilities to cover MES functionality. But here’s what you risk by not integrating with a modular MES like PICO:

• Lost Time and Productivity: Manual processes like paper-based work instructions and tribal knowledge transfer slow down onboarding, troubleshooting, and audits.
• Quality and Traceability Issues: Without centralized data, root-cause analysis of defects becomes a matter of guesswork. Customers may even require traceability that SCADA alone can’t provide.
• Technical Debt: Custom-coded solutions in Ignition may work temporarily but are hard to scale or maintain, especially with limited developer resources.

The opportunity cost of not integrating with PICO is real–and growing as customers demand more visibility, quality, and accountability.

How PICO's Machine Connectivity Works

PICO connects with machines through OPC or direct PLC connections to:

🚨 Trigger the start of a machine cycle

✔️ Subscribe to or periodically check a machine's status

📊 Instantly read data from the machine

🔁 Write and send data to the machine

By integrating machines with PICO, their data is unified with the data from manual assembly tools to provide manufacturers with a holistic view of production. 

⏯️ Watch this full demo on how machine connectivity is managed in PICO:

The Bottom Line

If you’re building custom SCADA or HMI apps and have developer bandwidth, Ignition SCADA remains a powerful foundation for automation. But if your operations rely heavily on manual processes, or if your traceability and reporting are lagging behind, it’s time to consider MES integration.

PICO adds the essential human layer–operator guidance, process validation, compliance tracking, and intuitive reporting–without replacing your existing system or requiring a single line of code.

Together, Ignition + PICO delivers a harmonized approach to automation that empowers both your machines and your people.

Ready to unify your SCADA and MES?

• Sign up for free PICO digital work instructions to start digitizing your processes.
• Book a demo with our team to learn more about integrating Ignition (and other factory systems) with PICO.