PlantRun connects directly to your assets to determine whether they are running or stopped in real-time. Product and reject counts can be monitored alongside shift patterns, production runs, etc. This gives you complete visibility of your manufacturing processes.

Every PlantRun system relies on accurate counting to monitor production effectively. These counts can be captured through various methods, including sensors, speed readings, temperature monitoring, weight measurements, and other key metrics that indicate when a product has been made.

By recording this data in real time, PlantRun eliminates the need for manual tracking, ensuring precise and automated production monitoring. This not only improves efficiency but also provides valuable insights that drive better decision-making.

Determining whether a machine is running or stopped can be as simple as picking up an on / off switch or relay.

If a pulse count is generated every time a product is made, box filled etc, it can also be used to automatically determine whether the asset is running or stopped. As long as pulses continue to be received the asset is running, if they stop for a period of time the asset is stopped. This approach has the advantage that PlantRun can now determine production throughput, as well as utilisation. 

For some assets, for example a laser cutter, PlantRun may receive a pulse count every time a new sheet is fed in. If the machine is working on that sheet for an extended period of time a seperate run / stop signal will also be required.

PlantRun can count products in multiple ways, depending on the machine type and available signals.

Direct Machine Signals: Many machines have built-in outputs that signal each completed cycle or product. PlantRun connects to these to automatically record production.

Sensors: Where a direct machine signal isn’t available, sensors such as proximity switches, optical sensors, or beam-break sensors can be installed to detect and count each product as it is completed.

Encoder or Pulse Counting: For continuous production processes, encoders or pulse signals can be used by PlantRun to calculate product length (m) or area (m²).

Operator Input: In some cases, production may be manually counted by operators using a PlantRun touchscreen interface, particularly for jobs with irregular output. This helps ensure counts are accurate, with real-time data visible on dashboards and reports.

PlantRun can also track rejects through automatic measurements or manual entry, providing a true measure of good production vs. waste.

With PlantRun, a sensor positioned on a conveyor detects each product as it moves past. This signal is instantly transmitted to the PlantRun system, where the data is processed and displayed in real-time, providing immediate insights into production performance.

While single-product counting is ideal for continuous, high-volume manufacturing, PlantRun also supports batch-based production tracking. For instance, if products are packed in groups—such as six items per box—it can be configured to register one count as six units, allowing direct correlation to the start of the line.

Beyond simple counting, PlantRun enables data conversion to different units for more meaningful reporting. Instead of displaying just the number of units, it can convert counts into alternative measures, such as kilograms for bulk goods or meters for materials like timber. Whether using a sensor to count individual items or a measuring wheel to track total length, PlantRun ensures production data is always relevant and actionable.

Every stoppage—whether due to a breakdown, material shortage, or planned maintenance—is recorded by PlantRun and available for analysis.

In fully automated mode, downtime reasons can be assigned automatically based on machine signals or system logic, removing the need for manual input.

Often, the operators running the asset have a better insight into the root cause of a stoppage. In this case PlantRun will prompt them to select a reason on a touchscreen interface. A predefined tree structure allows for grouped reporting of types of downtime reason, and any reason can be added to a category with use of flags.

Even short stoppages are recorded, but capturing the reasons for these micro-stops has the potential to slow production. Therefore PlantRun automatically assigns these reasons to its own category.

The wealth of data available across the site allows production teams to quickly identify recurring issues, make informed decisions, and take action to reduce lost time.

Capturing the reason for a stoppage at the time it happens ensures the data is more accurate. PlantRun can use interlocking to prevent an asset from restarting until a reason for the stoppage has been entered.

Typically an interlock relay is provided for each asset which is connected to the start circuitry on a machine. Excessive use of this would result in more production stoppages, so PlantRun only activates the relay following a significant stoppage.

Interlocking is not suitable for all types of machines, but its benefits mean it is always worth considering.

The diagram above shows a machine changing from a running state to a stopped state. After a significant stoppage (a configurable maximum short stoppage time) an interlock can be activated. On entry of the reason for the stoppage the interlock is released and the machine changes back to a running state.

PlantRun makes real-time and historical production data easily accessible across your site, ensuring that the right people have the insights they need to improve efficiency and performance.

The PlantRun system provides a comprehensive view of real-time production metrics to keep your team informed and responsive. Installed on existing office PCs, the Remote ViewStation software delivers detailed production data, helping to identify trends and improve efficiency. SmartView application software extends this capability by allowing flexible monitoring and management via tablets, smartphones, or modern web browsers, ensuring that key production data is accessible even when on the go. To enhance communication and responsiveness, the system can generate automated email reports summarising key production metrics. Additionally, maintenance or support requests can be sent via SMS text messages, ensuring that the right people are alerted promptly. By integrating these elements, the PlantRun system enhances operational efficiency and promotes a collaborative and proactive work environment, helping you meet your production goals effectively.

For greater visibility, large TV screens can be strategically placed around your shopfloor. These screens display real-time production information, KPIs, and even weekly health and safety messages. The content cycles through the pre-defined selection to keep your team informed and motivated.

For production managers and team leaders, PlantRun provides web-based dashboards that can be accessed from any authorised device on the network. These dashboards offer real-time monitoring of asset utilisation, downtime analysis, production counts, and energy consumption, all presented in a clear and customisable format. Reports can be generated automatically or on demand, with scheduled email distribution ensuring that key stakeholders always stay informed.

In the maintenance workshop, PlantRun provides real-time visibility of machine status, highlighting not only running and stopped states but significant breakdowns and callouts from the machines.

Reasons for stoppages can be updated and recurring faults can be identified and addressed proactively.

If energy monitoring is enabled, maintenance teams can also track excessive energy consumption and identify machines that may need servicing or optimisation.

Work In Progress (WIP) can be seen in real-time giving predictions as to the end of jobs, alongside detailed information about the works orders recently completed.

Job tracking data ensures planners know exactly how much work has been completed, how much remains, and whether production is ahead or behind schedule. This helps prevent bottlenecks and ensures that deadlines are met. If machines experience repeated stoppages, downtime reports help identify problem areas so schedules can be adjusted proactively.

Production rate data allows planners to compare actual vs. expected output, making it easier to predict delivery times and adjust plans accordingly. If production is running slower than expected, teams can investigate issues such as machine inefficiencies, material shortages, or operator delays.

For factories running multi-product lines, PlantRun provides product changeover tracking, ensuring planners know when a line will be ready for the next job. If integrated with ERP/MRP systems, PlantRun can also feed real-time production data directly into planning software, reducing reliance on manual updates

PlantRun data is available all the way to the top. Multiple sites can be monitored to give real-time overview of all production facilities, in one place.

A director wants a clear, high-level view of performance across the entire factory, without getting lost in the details. PlantRun provides instant access to key metrics that matter most to leadership, ensuring they have the insights needed to drive efficiency, profitability, and strategic decision-making.

From their office or on the go, directors can access real-time dashboards displaying factory-wide OEE (Overall Equipment Effectiveness), utilisation rates, and production output. They can see whether targets are being met, where bottlenecks are occurring, and how downtime is affecting overall efficiency.

Performance trends over time allow directors to track improvements, compare shifts, and evaluate whether investments in new equipment or processes are delivering the expected returns. Reports on energy consumption, waste levels, and operational costs provide critical data for cost control and sustainability initiatives.

A PlantRun system can be configured in numerous ways to meet the site requirements.

The diagram below illustrates an example PlantRun system, highlighting the necessary infrastructure and showcasing potential configurations tailored to different operational requirements.

The PlantRun software needs to run on a server, this can be on premises, a virtual in a server room, or a PC in a production office.

PlantRun's data needs to be accessible on existing office PC's through Viewstation, Workstation and SmartView connections, and on TV screens with Display Nodes.

Integration with ERP/MES systems allows Works Order / Job details to be available on the shopfloor. Connections to SCADA systems such as Prodigy SCADA further augments its capabilities.

The diagram outlines two distinct areas, Area A and Area B, each offering unique solutions based on specific needs.

Area A shows the PlantRun infrastructure when using DTM04 outstations. DTM04 Outstations are compact rugged panels that feature a display and keypad to enable staff to interact with the system without leaving the area. Outstations have wipe clean alphanumeric keypads and multi-line displays housed in rugged enclosures including versions in stainless steel suitable for 'clean' and 'harsh' environments. Built in I/O allows for simple screw terminal connection of signals from machines/assets, data and power for straightforward installation.

Area B uses more graphical interfaces, including PC, tablet and touch screen displays. These interfaces offer much more visual displays and keep operators in the loop with production performance, through their ability to display all important data on one screen. These displays are fully customisable allowing more functional flexibility than Outstations. They have the advantage of providing enhanced graphical capability, for example, allowing images to be displayed to reduce operator error (is the correct product being run?). IP rated stainless steel versions are also available for applications that require clean down such as food and pharmaceuticals.

Dependent upon options ordered, these interfaces allow:

• Staff to log on and off – track staff time at the machine

• Selection of product/batch code – track against product/job number etc.

• Selection of downtime reasons from a multi-level menu

• Call for assistance - for faster response from an engineer, team leader etc.

• Entry of scrap values

Barcode scanners and RFID readers can also be used to minimise operator errors (optional functionality).

The Outstations are connected to the central PlantRun Server through a DTM-C2 communication panel. These provide both communications links and power to the Outstations to ensure that they are not reliant on power from the assets themselves.