I. Status Confirmation and Preparation
Manually document the error code of the current synchronisation failure, the scope of affected devices, and the time of the most recent successful synchronisation.
Backup Current State: To prevent data loss during operation, manually export the local RC calibration cache data on the SCADA side and a snapshot of the presently synchronised RC parameters on the MES side.
Confirm Fault Scope: Manually test the network connectivity between the MES and SCADA to determine whether it is a single device failure or a full-link failure.
II. Recovery of Physical Links Manually
Verify the status of the link indicator at both endpoints of the network port. Confirm link connectivity by manually unplugging and replugging the network cable and replacing the RJ45 connector if the indicator is not illuminated.
Reconfigure the port VLAN and manually transfer the communication network cable to a spare port if the current switch port is unresponsive.
Check the routing of the communication network cable manually to ensure that there is no significant electromagnetic interference. Temporarily modify the routing to avoid power lines if necessary.
III. Recovery of Manual Communication Protocols
Confirm that the OPC UA/MQTT driver versions are fully compatible by manually verifying the interface protocol versions of the MES and SCADA. Access the industrial firewall backend and manually add a rule to permit access to the dedicated communication port for RC calibration data, ensuring that the port is not blocked.
Confirm that both ends are within the same communicable network segment, modify conflicting IP addresses to available network segments, and manually verify the IP addresses at both ends.
IV. Recovery of Manual Data Mapping On both the MES and SCADA sides, manually verify the RC parameter register addresses and point IDs, rectifying any misaligned point configurations.
To resolve data garbled issues, manually align the numerical types, units, and decimal places of the RC calibration data on both sides.
Manually compare the versions of the RC calibration baseline parameters on both sides, synchronising the most recent baseline parameters from the MES side to the SCADA side line by line, thereby completing version alignment.
V. Data Recovery and Manual Service Confirm that the SCADA data acquisition service and the MES synchronisation scheduling service are restarted manually and that they operate without any errors.
To release the consumption channel, manually remove non-core historical production data messages from the message queue.
The data completion process is completed by manually comparing the data timestamps at both ends and manually entering the missing RC calibration data from the SCADA side into the MES system line by line.
VI. Manual Verification Following Recovery
Trigger the RC calibration data upload operations manually three times to verify that the data can be synchronised properly with the other end.
Confirm that the RC calibration data is 100% consistent and devoid of deviation by manually verifying the hash values on both sides.
Record all operation steps and parameter change information manually for this manual recovery and archive them in the department's operation and maintenance knowledge base.
This entire manual recovery process is not dependent on automation tools and can be rapidly implemented in industrial sites without script support. Ninety percent of common defects can be repaired within twenty minutes.
