We connect machine controllers, PLCs and IoT gateways to production records in your system.

Production figures written in a register at the end of a shift are late, rounded and sometimes guessed. Machines already know how many pieces they made and when they stopped. Reading that data directly gives supervisors and owners an accurate picture of output and downtime while there is still time to act on it.

What we build with it

  • Recording machine output counts against a work order
  • Capturing downtime with a reason code
  • Monitoring process parameters during a run
  • Feeding production dashboards from actual machine data

How it works

  1. We survey your machines to see what data each one can provide and through which protocol.
  2. A gateway or small computer on the shop-floor network reads counts, states and readings from the machines.
  3. The gateway sends the data to the system at short intervals, holding it locally if the connection drops.
  4. The system links the data to the running work order and machine, and records stoppages as downtime.
  5. Operators add a reason for each stoppage on a simple screen, and dashboards show output against plan.

Data exchanged

  • Output counts
  • Machine state and downtime events
  • Process readings such as temperature or pressure
  • Timestamps and machine identifiers

What is needed to set it up

  • Machines exposing data via OPC UA, Modbus, MQTT or a vendor API
  • An IoT gateway or local agent on the shop-floor network
  • Mapping between machine signals and work orders

Good to know

  • Older machines without a data port can often be fitted with simple sensors, such as a counter or current sensor, to report output and running state.
  • The connection reads data only. We do not send commands to machines unless that is specifically designed and agreed with your maintenance team.
  • Shop-floor networks should be kept separate from office networks, and the gateway is set up with that in mind.