Machine state and OEE
Run, idle, stop and fault from the line, with availability, performance and quality on the same shift.
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Manufacturing
Machine state, energy, quality and traceability for process and discrete plants. The pilot programme is open.
The plant
Discrete lines and process plants: presses, assembly, chemicals, plastics, paper. Agro-processing and food plants have their own pages. A factory that does not match a specialist layout starts with energy and vibration on the main drive, then the probes the survey adds.
Factory dashboards
Each plant type has its own view. Open one.
Manufacturing
Automotive assembly
Press and conveyor health, and the paint booth climate when the plant paints.
Manufacturing
Batch chemicals
Reactor temperature, the charge tank and the transfer. This logs the batch. It does not replace the safety system.
Manufacturing
Electronics
Reflow temperature, the dry cabinet, and the humidity the placement cell actually needs.
Manufacturing
General processing
A first line when the plant does not match a specialist layout: energy and vibration on the main drive, then the probes the survey adds.
Manufacturing
Metal fabrication
The press or spindle, the coolant sump, and the compressor that usually hides the energy.
Manufacturing
Packaging
Web dryer temperature, the main drive, and the humidity that curls board.
Manufacturing
Plastics extrusion
Melt temperature and gearbox vibration on the extruder. The resin dryer is included when the plant dries its own material.
Manufacturing
Pulp & paper
Stock flow, dryer temperature and the chest that feeds the machine.
Manufacturing
Textiles
Shed humidity, the dye bath when the mill dyes, and the stenter when finishing stays on site.
Where a first line usually starts
- Unplanned stops are found when someone walks the line, not when the motor current changes.
- Energy cost per unit is estimated from the monthly bill.
- Quality drift shows up in the lab book after the batch has moved on.
- Shift logs are written by hand and retyped into the ERP.
Condition monitoring
Vibration and temperature on drives, so maintenance is triggered by the machine rather than a fixed calendar.
Energy and steam
Feeder meters, boiler and generator demand, turned into energy per unit once output is known.
Process environment
Temperature, humidity and time through the stages that decide product quality.
Tanks and silos
Level on work tanks and raw-material silos, tied to the batch that is running.
Cold rooms
Hold temperature and door state where the product must stay cold.
From the sensor to the action
- 01
Sense
Sensors and meters on the line: temperature, humidity, vibration, motor current, energy, level, door and weight.
- 02
Connect
An industrial gateway reads Modbus RTU and RS485 and publishes MQTT or HTTPS. A site router covers Ethernet PLCs and LTE failover where the plant LAN needs an uplink. Hardware is multi-vendor (LoRaWAN, Modbus, 4G/LTE).
- 03
Platform
Industrial IoT checks the device token, stores the reading, and shows it on the floor, energy, OEE and maintenance screens.
- 04
Insight
Alerts, OEE, energy per unit and condition trends for the shift. Demo readings stay labelled until a real gateway is commissioned.
- 05
ERP action
The same events are designed to become FactoraERP work orders, downtime, batch quality, energy cost and stock. That exchange is part of the pilot, not a live claim.