Plant operations
For production and maintenance managers. OneIoT follows each process on a line against its limits. When one leaves them, it tells the line's HMI to stop, where the HMI accepts a stop command, puts the reason on the operator's screen, reaches the right people, and records the stop against the process that caused it.
Production lines and utilitiesOperations: Industrial control
What's at stake
Most of a stop isn't the fault. It's finding out what happened, and who knows.
to get production running again after an unplanned stop, up from 49 minutes five years earlier.
Siemens, The True Cost of Downtime 2024 (vendor report) ↗a month lost to unplanned downtime in an average large plant.
Siemens, The True Cost of Downtime 2024 (vendor report) ↗a month per plant, on the same survey.
Siemens, The True Cost of Downtime 2024 (vendor report) ↗“I had a customer call and complain they had a leak in their accumulator bank, the alerts had been going off for a month.”
A stop you can explain is a stop you can stop repeating.
One stop on Line 1
The extruder head on Line 1 starts to run hot on a Tuesday afternoon. This is what happens next, and what's on record at Wednesday's production meeting.
Line 1, one Tuesday afternoon · sample data
Extruder head zone 3 creeps toward its 347 °F (175 °C) limit. Still inside it: recorded, nothing stopped.
Above 347 °F for 60 seconds. OneIoT tells the line's HMI to stop Line 1, and puts the reason on the operator's screen, with the last time it happened.
The shift supervisor and the maintenance engineer on call are alerted on SMS and push.
Maintenance acknowledges and is at the extruder.
A heater relay in zone 3 stuck on. Replaced.
Line 1 restarts. The stop is on record against extrusion: 29 minutes, 590 ft of scrap, the reason and who fixed it.
The incident record · sample data
The line stopped in a minute, not at the end of the shift.
Operations in this industry
From a reading on the line to a stop through its HMI, and the pump stations behind the plant: the operation has its own page.
The record
When the plant manager asks why Line 1 lost half an hour on Tuesday, the answer is already written, by the line.
Downtime is recorded the way ISO 22400 defines it for manufacturing KPIs: planned and unplanned kept apart, each with its duration and reason.
The line stops itself, and the reason is on the operator's screen.
Stops are reviewed by reason, process and shift, from the record, not from memory.
The biggest loss is the one you work on, and OEE shows whether it's gone.
Where it runs
6 processeson one cable line, in production
Elogictech Edge built its manufacturing-intelligence solution on OneIoT and runs it at Gloster Cables: every process followed against its limits, the line stopped through its HMI with the reason on screen, and OEE by line and process.
We connect one line's processes, set their limits and their people and, where your HMI allows, the stop, and run it. You can start monitor-only, with the stop switched off. At the end you have:
What goes in
OneIoT Edge reads controllers, PLCs and meters over Modbus, OPC UA, MQTT Sparkplug and HTTP, with I/O cards for sensors and relays, and keeps control running offline.
Line status and stoppage reasons come in from the HMI already on the line, and a stop goes back through it with the reason on screen.
Each process's limits, how long it may stay out, and who hears first.
OneIoT AIOneIoT AI investigates each alarm as it arrives. Where it acts, it acts only through the control program on site, within that program's limits.See OneIoT AI
Where to start
Call
Outline
4 weeks
Results
Start with one line: 4 weeks at a fixed fee. Then a monthly price per site, on a 12-month term.
Making industrial machines? Put OneIoT in them, under your brand
