Production Line Monitoring System

Accurate production line monitoring enables you to maximise efficiency, capacity, improve management as well as inform and motivate your staff.

PlantRun gives you live production metrics including OEE that can be viewed on PC’s, laptops, tablets, smart phones and large screen displays enabling better management and informing and motivating your staff. Wasteful manual data collection is eliminated freeing your staff to do more value added work. Paperless manufacturing becomes achievable.

This is achieved by capturing data directly from your production line. Dependent upon the make up of the production line it may be treated as a single asset (by counting product coming off the end of the line) or as a number of discrete or linked machines whereby each asset is monitored individually. This is true particularly if the line varies or is routed differently dependent upon the product being made.

production line data terminalIn its simplest form PlantRun requires only one signal that identifies when a product has been made. This signal can come from an existing point on the line (counter/lamp/relay etc) or by the addition of a low cost sensor. This way of connecting to the line makes it straightforward to install to any type, make or age of line and minimises costs. Scrap product can be captured in a similar way or entered manually at the line or using any system PC. Monitoring of multiple points or assets that comprise a line enables enhanced data capture including yield value.

PlantRun can also connect directly to machine controllers and PLC’s and incorporate input devices such as bar code scanner, swipe card, RFID. Data is stored in Access or SQL compatible databases for export to third party systems like ERP and MES.

All line events are recorded including operator, shift, product changes as well as all downtime, including short or micro stops. Longer stops are assigned a reason and any number of reasons can be set for each line so you have total flexibility in what is tracked.

One or more operator interfaces are sited adjacent to each production line. Interfaces include compact rugged outstations that feature a keypad and display as well as touch screen and PC options. Existing PCs and touchscreens can be utilised.

Interfaces allow your staff to interact with the system without leaving the production area to;

• Log on and off - track operator efficiency
• Select product, job/works order
• Select downtime/stoppage reasons - unlimited reasons on a per machine basis
• Enter scrap/rework - accurately track scrap
• Call for assistance – engineer/team leader/materials/tool setter etc.
• Read information including target and actual production

Track and analyse production line efficiency

Built in analysis tools allow you to drill down on a single line issue, compare line performance, quickly summarise production line KPI’s over any period, filter against operators, products, shifts etc. Industry standard reports are ready to use, can be generated automatically to pdf for easy access and emailed to groups of users – saving time and hassle for regular meetings.

As well as giving you accurate live information PlantRun enables faster response to production problems. Staff can call for assistance straight from the operator interface without having to leave the line. The system will send the call via SMS text, email, public address, show it on large screen displays as well as the alarm banner on any system display. System alarms can also be triggered automatically when any parameter goes out of limits.

Plantrun can also handle the more complex requirements of process monitoring (temperature, pressures, vacuum, humidity, flow), utility monitoring (electric, gas, water, steam, compressed air) as well as any level of production control required.

All this is backed up by high quality technical support, training and maintenance contracts from one of the longest established suppliers of industrial automation software and systems.

Designed and developed to be cost effective, current users report payback in less than twelve months as typical.

For a no obligation budgetary 'quick price' please complete the form below.
Your email address: *
First Name: *
Last Name: *
Company Name: *
Country: *
Telephone: *
Project details: Number and types of asset(machine/line/cell/manual), functionality required etc.