Machine data collection and overall equipment effectiveness (OEE)
Collect run/stop status, part counters and fault codes from PLCs or added sensors, then calculate OEE per shift to see where the losses are.
Common problems
- Production figures are written by hand at the end of the shift, late and inaccurate.
- Nobody knows how many minutes each machine stopped per shift, or why.
- Old machines have no PLC, or PLCs come from many different brands.
- Data exists but sits on separate HMIs and is never consolidated.
How Uptrol does it
- 01
Pick questions and data points
Agree on the 20–50 data points you actually need instead of reading every PLC variable.
- 02
Connect each machine type
Read PLCs over OPC UA, Modbus TCP or vendor drivers; add current sensors and counters to machines without a PLC.
- 03
Pilot on one machine
Check the figures against the HMI and production log before scaling out.
- 04
Dashboards and OEE
Line dashboards, OEE per shift, Pareto of stop reasons.
What you get
Run, stop, fault in real time
A timeline per machine, including short stops.
Availability × Performance × Quality
Per shift and product, each loss type separated.
A short list of reasons
From PLC fault codes or picked quickly by the operator on screen.
Shift, daily, monthly reports
Emailed automatically, exported to Excel for planning.
Push figures to ERP, MES
Via API or files in your system’s format.
Read-only, never writes to PLCs
The machine’s running program is never changed.
A good fit when
- You have a few to a few dozen machines whose output you need to track.
- Management needs objective figures instead of handwritten reports.
- You are preparing for an MES but want to start small.
What do you need to monitor or automate?
Tell us about your plant, station or server room. We will reply with a concrete approach and next step.