Connected machines
Status and alarms from lines and utilities land on one platform.
Manufacturing
See line equipment, quality and downtime as they happen.
- Device connectivity
- Production visibility
- Quality traceability
- Predictive maintenance
4–8 wksfirst scenario live
50+projects delivered
6protocol families
On-premdata stays local
The plan is built around machine data: live status, a reason for every stop, batch traceability, and maintenance based on condition rather than the calendar alone.
Pain Points
- 01
Stops are explained only after someone walks the line
- 02
Output and defects wait for the end-of-shift report
- 03
A bad batch cannot be tied back to machine and material
- 04
Calendar maintenance misses real wear and stops healthy machines
How the system is put together
Keep the equipment you have, connect the data first, then split the views by role. The connection layer takes the most work, and it is where most of our effort goes.
L1
Devices
- PLCs and machines
- Instruments
- Utility meters
- Scanners and vision
- AGV and AS-RS
PLCs, meters, access control, cameras and sensors already on site. Read what is readable, add a module where it is not, and leave the existing control system alone.
L2
Connection
Modbus · OPC UA · MQTT · HTTP · GB28181 · SDK
Common protocols connect directly. The gateway handles protocol mapping, local buffering and backfill, so the data does not break.
L3
Platform
- Device registry
- Time-series data
- Alert rules
- Work orders
- Roles and audit
Device registry, time-series data, alert rules, work orders, roles and audit in one back end that serves several scenarios.
L4
Applications
- Device connectivity
- Production visibility
- Quality traceability
- Predictive maintenance
- Manager view
- Phone actions on site
- Narrow external lookup
Data is collected once and reused by every scenario added later, which is why the connection layer has to be done properly the first time.
What we deliver
Shift board
Output, cycle time and downtime show during the shift.
Traceability
Batch, machine and process values stay linked for later lookup.
Condition maintenance
Vibration and temperature point to machines that need work.
Where it fits
Discrete workshop - status and stop reasons
Run, alarm and stop states carry a reason code, so downtime and the output gap are calculated rather than explained.
Assembly line - cycle time and defects
Station cycle time, WIP and defect types come up live, so the constraint is visible during the shift.
Utility rooms - air, water, power
Air, water, power and steam split by workshop and line, with low pressure or odd consumption raised early.
Traceability - batch to machine
Batch, machine, process values and material lot sit on one record, so a look-back takes a few steps.
What a real day looks like
Not a feature list: what actually happens in a day. These four steps are the common shape of such projects.
- 14:22 Stop
Line 3 spindle stops; the operator picks "tool change" on the tablet and the clock starts.
- 14:23 Cause
The stop is attached to the machine and reason code, and the output gap for that window is computed.
- 14:30 Visible mid-shift
The team leader sees it on the shift board instead of learning at handover.
- Month-end review
The same cause appears 11 times and ranks first, which changes the next maintenance plan.
Delivery rhythm
Every stage has a checkable output. No six-month build followed by a single review.
- Week 1
Site survey
Walk the site, list devices, available ports and current systems, and mark what reads directly versus what needs a module.
- Week 2
Pick the first scenario
Rank the ideas by impact, feasibility and dependencies, then choose one that proves value without dragging in every department.
- Weeks 3-5
Connect and wire up
Gateways connect devices, data lands on the platform, and alert rules, roles and recipients are configured for a small internal group.
- Weeks 5-7
Pilot
One team or one building uses it for real; rules and screens change with feedback until false and missed alarms settle.
- Week 8
Accept and repeat
Check every acceptance item, finish documentation and training, then decide which buildings, lines or sites come next.
Acceptance is these three lines
The three items below come from projects of this kind and go into the acceptance sheet, instead of relying on a general impression.
Every stop has a time and a reason
Quality issues trace to machine and batch
Maintenance follows machine condition
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Questions
Many machine brands with different protocols?
Common brands go through OPC UA, Modbus or FOCAS; older machines get a gateway reading IO or current. The list of machines and available ports decides each case.
Will data collection disturb production?
Read-only: no control commands are written back. The gateway buffers locally when the network drops and backfills afterwards.
Does it need a shutdown?
Most wiring fits a planned window, typically one to two hours per machine. Machines that can stay running are wired live.
How does it relate to our MES and ERP?
The platform owns machine data and causes, MES keeps orders and materials, ERP keeps the books. They align through interfaces, with no double entry.
How soon is there something to see?
One line first: a mid-shift board in four to six weeks, then other lines once the numbers hold up.
Free diagnosis
Tell us where it gets stuck
Leave one contact. We send how similar projects were handled plus a scenario list. If it is not worth doing, we say so.
- A 30-minute call to judge whether it is worth doing
- A workable scenario list and timeline
- No consulting fee up front
Get Industry-specific Solution
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