Real-Time Production Monitoring for Smart Manufacturing
Connect machines, PLCs, sensors and production systems to monitor production output, machine status, downtime, quality, OEE and production targets in real time.
SCHEDULE A DEMOIoT Based Production Monitoring System
An IoT-based Production Monitoring System automatically captures machine and production data directly from the shop floor and brings it into a centralized monitoring platform. By connecting machines through industrial communication technologies and IoT gateways, manufacturers gain accurate, real-time visibility into production performance without relying on manual data entry.
Machine and production data can be collected automatically from:
- ✓ PLCs & machines.
- ✓ Sensors.
- ✓ Barcode scanners.
- ✓ IoT devices.
- ✓ Existing automation systems.
Real-Time Production Analysis
A centralized production dashboard provides real-time visibility into shop-floor performance, helping operators, supervisors, and management track production from a single screen.
Production Target vs Actual Monitoring
Compare planned production with actual output in real time to identify shortfalls early and take corrective action before the shift or production period ends.
- Monthly production targets
- Weekly production targets
- Daily production targets
- Shift-wise targets
- Production line targets
- Individual machine targets
Machine Downtime Monitoring
Track machine downtime in real time to identify production losses, recurring issues, and opportunities to improve machine availability and productivity.
- Machine-wise downtime
- Production line-wise downtime
- Shift-wise analysis
- Downtime reason
- Breakdown category
- Duration and frequency
Predictive Maintenance
Use machine condition data to detect abnormal behavior and potential failures early, supporting a shift from reactive to condition-based maintenance.
- Vibration monitoring
- Current monitoring
- Temperature monitoring
- Pressure monitoring
- Voltage monitoring
- Motor condition monitoring
OEE Monitoring
Monitor Overall Equipment Effectiveness (OEE) to understand machine and production efficiency across machines, lines, shifts, products, or the entire plant.
- Machine availability
- Performance
- Quality
- OEE percentage
- Production losses
- Downtime, speed, and quality losses
Monitor Manual, Semi-Automatic and Automatic Machines
Monitor production across manual, semi-automatic, and fully automatic machines from a single platform. Capture production, quality, downtime, and machine data regardless of the automation level.
Manual Machines
Operators can digitally record production and machine information, replacing manual registers with accurate, centralized data.
- ✓ Operator production entry
- ✓ Production quantity
- ✓ Quality output
- ✓ Downtime information
- ✓ Production target tracking
Semi-Automatic Machines
Capture machine signals and production data automatically while allowing operators to enter additional production or quality information when needed.
- ✓ Machine running status
- ✓ Production output
- ✓ Quality output
- ✓ Production target tracking
- ✓ Downtime monitoring
Automatic Machines
Connect fully automated machines through PLCs, controllers, sensors, and industrial protocols for real-time production monitoring.
- ✓ Automatic production count
- ✓ Machine running status
- ✓ Downtime monitoring
- ✓ Quality monitoring
- ✓ Machine breakdown alerts
Production Monitoring Enterprise Integration
Connect production monitoring with machines, shop-floor systems, and enterprise applications to create a connected manufacturing environment. Integrate real-time production data, alerts, traceability, and business information through a centralized platform.
PLC & Machine Integration
Connect manual and automated equipment using PLCs, IoT gateways, sensors, counters, and suitable communication interfaces to capture machine data.
- PLC-based machine integration
- Machine signals
- IoT gateways
- Signal acquisition devices
- Existing and new equipment
Industrial Protocol Integration
Collect machine data through commonly used industrial communication protocols and bring information from different equipment into one platform.
- OPC UA
- Modbus
- PROFINET
- Other industrial protocols
Andon Integration
Connect production monitoring with Andon systems to generate real-time alerts and help teams respond quickly to production interruptions.
- Machine breakdown alerts
- Production stoppage alerts
- Excessive downtime
- Quality issues
- Target deviations
- Operator assistance
Barcode-Based Production Traceability
Integrate barcode scanners to capture product and process information, enabling production monitoring with product-level traceability.
- Product serial number
- Part number and work order
- Production quantity
- Station and machine information
- Production timestamp
- Operator information
ERP Integration
Connect the production monitoring platform with ERP systems to exchange production, order, material, and quality information across the enterprise.
- Production and work orders
- Product master and material information
- Production targets
- Production confirmations
- Quantity produced
- Rejection and serial number information
Key Features of Production Monitoring :
Turn shop-floor data into real-time production insights by connecting machines and shop-floor systems directly to an automated monitoring platform. Eliminate manual registers and delayed spreadsheets while improving production visibility, data accuracy, and decision-making.
IoT Machine Connectivity
Collect machine and production information directly from connected equipment, PLCs, sensors and IoT gateways.
Production Monitoring
Monitor production quantity, target, actual output, quality and production achievement in real time.
Predictive Maintenance
Integrate vibration, current, temperature and other machine-condition sensors for predictive maintenance.
All type Machine Support
Monitor manual, semi-automatic, and automatic machines from a single production monitoring platform.
Mobile App
Monitor production status, machine performance, downtime, OEE, and alerts in real time from anywhere using a mobile app.
Production Dashboard
Gain real-time visibility into target vs. actual production, machine downtime, predictive maintenance, and OEE performance from one centralized dashboard.
How IoT Based Production Monitoring Works
IoT-based production monitoring replaces manual data collection with automated machine and production data capture. Connected equipment sends real-time information directly to a centralized monitoring platform.
Step 1: Machine Data Generation
Machines generate production, operating status, downtime, and performance data during the manufacturing process.
Step 2: Data Collection
PLCs, sensors, and IoT gateways collect machine and production data directly from connected equipment with minimal manual intervention.
Step 3: Data Transmission
Collected machine data is securely transmitted from the shop floor to the centralized production monitoring platform.
Step 4: Real-Time Production Monitoring
The platform processes the incoming data and provides real-time visibility through dashboards, reports, and production analytics.
Step 5: Production Insights & Action
Supervisors and management can identify production gaps, downtime, and performance issues quickly to improve operational efficiency.
Mobile App for Production Monitoring
Monitor production performance anytime, anywhere through a mobile application. Supervisors and production managers can stay connected to real-time shop-floor information even when away from the production floor.
Access critical production information including:
- Current production status
- Target vs. actual production
- Machine status and downtime
- Production achievement
- OEE performance
- Production alerts
- Line performance
Why to choose Production Monitoring?
An IoT-based Production Monitoring System connects the shop floor with management systems for real-time production visibility. It replaces delayed manual reporting with accurate, automated, and actionable production insights.
Real-Time Production Visibility
Get instant visibility into machine, line, and production performance from a centralized platform.
Reduced Downtime & Production Losses
Identify downtime, breakdowns, and production losses quickly to minimize interruptions and improve output.
Improved OEE & Machine Utilization
Track availability, performance, and quality to improve OEE and maximize machine utilization.
Accurate Production Data
Automate data collection to reduce manual entry, improve data accuracy, and streamline production reporting.
Connected Manufacturing
Connect machines, operators, shop-floor systems, and enterprise applications for a more integrated operation.
Data-Driven Decision Making
Use real-time dashboards, analytics, and performance insights to make faster and smarter production decisions.
Our Trusted Clients
We’re proud to collaborate with industry leaders and innovative companies
Digitize Your Production Monitoring
Connect your machines, monitor production in real time, measure OEE, reduce downtime and build a connected Industry 4.0 manufacturing environment.
