OEE & Machine
Monitoring System
Connect legacy and modern manufacturing machines to a centralized cloud dashboard. Track OEE (Availability, Performance & Quality) in real-time, detect anomalies before critical failures occur, and reduce unplanned downtime by up to 40% — without touching a single line of PLC code.
System Capabilities
Standardize operations with multi-machine tracking, protocol translations, and diagnostic interfaces.
Real-Time OEE Tracking
Calculate Overall Equipment Effectiveness (OEE = Availability × Performance × Quality) automatically using live data from production lines. Detect micro-stops, speed losses, and quality defects the moment they happen — not hours later in a spreadsheet.
Legacy Machine Compatibility
Monitor OEE on machines from any era — no PLC code changes, no equipment replacement. Communicates natively via Modbus RTU/TCP, CANopen, OPC UA, and custom serial protocols through ruggedized, optically-isolated gateways.
Predictive Alerts & Anomaly Detection
Set threshold-based alerts or enable ML anomaly detection to catch performance degradation before it collapses your OEE score. Receive instant notifications via SMS, email, or webhook — addressing failures before they become unplanned downtime.
Non-Invasive, Safe Deployment
Deploy OEE monitoring without stopping production or modifying your control systems. Optically-isolated gateway interfaces read machine telemetry in a read-only mode, shielding controllers from electrical noise and ground loops. Zero risk to existing PLC programs.
Historical Logs & OEE Auditing
Store minute-by-minute diagnostic data locally on the gateway edge or stream it into secure cloud repositories. Track OEE trends over time, identify recurring Six Big Loss patterns, and build a longitudinal dataset that powers root-cause analysis and shift-by-shift benchmarking.
Custom Factory Adaptors
No two factory floors are identical. We design customized sensor boards, carrier configurations, and enclosures matched to your specific machinery. Whether your plant runs CNC mills, injection molders, hydraulic presses, or conveyor lines — every machine contributes to your OEE score and gets monitored.
Seamless Gateway Routing
The architecture bridges legacy shop floor sensors directly to high-availability dashboards without complex infrastructure. Our hardware nodes read, isolate, and route messages safely.
- Optically isolated RS-485 / Modbus communication interfaces.
- Hardware security element storing credentials locally.
- MQTT/JSON payload transmissions with automatic cellular fallback.
Edge-to-Cloud Architecture
Legacy PLCs / Sensors
Communicating over Modbus, CANopen, or standard analog output.
AdaptNXT Rugged Gateway
Optically-isolated interface + local caching + secure cryptography element.
Cloud Dashboard / REST API
Real-time alerts, metrics database, and interactive visual interface.
Frequently Asked Questions
Everything you need to know about our Industrial Machine Monitoring System.
Yes — this is one of our core differentiators. We install optically-isolated edge gateways that read Modbus RTU/TCP, CAN-bus, or analog sensor signals in a completely read-only mode. Your existing PLC programs, safety interlocks, and control logic are never touched. Most deployments go live within days without any production shutdown.
OEE = Availability × Performance × Quality. The system tracks each component automatically from live machine data: Availability measures uptime versus planned production hours; Performance compares actual execution speed to target cycle speed; Quality counts good output versus total parts produced. The result is a single, real-time OEE percentage per machine, per line, or across your entire plant.
Industry benchmarks consider 85% OEE as world-class. Most manufacturing plants start between 40%–60% when they first begin tracking OEE accurately. A realistic first-year goal for most of our clients is to move from their baseline to 70%+ by addressing the top two or three loss categories identified by the system.
Typically 2–5 working days from hardware installation to your first live OEE dashboard. Our 8-week pilot programme is structured to give you baseline OEE data in Week 1, root-cause analysis in Weeks 2–4, and a measurable improvement target by Week 8.
Our gateway contains an integrated SPI Flash buffer, storing all machine telemetry records locally during any connectivity interruption. When connection is restored, buffered messages are published automatically — preserving your OEE dataset with no manual intervention and no data gaps.
Yes. The platform supports configurable downtime reason codes (planned, unplanned, changeover, maintenance, etc.) and can segment OEE by shift, operator team, machine, or production line. This shift-level visibility is essential for identifying which specific period is dragging down your overall score.
Yes. The cloud platform exposes a REST API and supports standard webhook event streams, allowing production counts, downtime events, and OEE scores to be pushed into SAP, Oracle, or custom MES systems. We also support manual CSV export for smaller operations that are not yet on a full ERP.
Absolutely. The gateway hardware incorporates a dedicated secure element chip to encrypt telemetry payloads and authenticate all TLS connections. Data is transmitted over MQTTS (port 8883) and stored in encrypted cloud repositories (AWS or Azure). No unauthorized entity can read or inject machine data.
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