Solution

SOL-08

Controls & Digital

Industrial Networking & Production Data

Machine connectivity, OEE and downtime data across mixed controls generations, with a defined IT/OT boundary.

Solution

Controls & Digital

Industrial Networking & Production Data

Machine connectivity, OEE and downtime data across mixed controls generations, with a defined IT/OT boundary.

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Architecture drawing of 14 machines connected through an edge gateway to a historian — FIG. 1
Illustrative application drawing · see the linked project record
SOL-08

Problem & outcome

What it solves

Problem & outcome

What it solves

The problem

Without reliable machine data, improvement work depends on spreadsheets and memory. Many plants also run flat, undocumented networks where a single fault or an IT change can stop production.

The problem

Without reliable machine data, improvement work depends on spreadsheets and memory. Many plants also run flat, undocumented networks where a single fault or an IT change can stop production.

Intended outcome

A reliable, shared picture of what each machine is doing and why it stops.

Typical rollout

8–20 machines per phase

Indicative range · confirmed per project

Typical rollout

8–20 machines per phase

Indicative range · confirmed per project

Engineering

Approach, applications and scope

Engineering

Approach, applications and scope

Technical scope

Engineering approach

We audit the existing network, segment it with a defined IT/OT boundary, connect machines through OPC UA and MQTT on edge gateways and agree downtime reason codes with operators before building reports.

Typical applications

OEE and downtime reporting
Energy and utility monitoring
Network segmentation and documentation
MES/ERP interfaces

Scope

Network audit and design
Edge gateways and historian
OEE and downtime dashboards

Technical scope

Engineering approach

Typical applications

OEE and downtime reporting
Energy and utility monitoring
Network segmentation and documentation
MES/ERP interfaces

Scope

Network audit and design
Edge gateways and historian
OEE and downtime dashboards

Evidence

Project records

Evidence

Project records

Line drawing of inspection and traceability stations

PRJ-0287

Automotive & Mobility

Inline inspection & traceability

Customer-reported defects reduced from 210 to 38 PPM, with an image and result stored against every serial number.

Customer-reported defects · PPM

Inspection time per part · ms

780

Read project record →

Production data architecture across the OT/IT boundary

PRJ-0196

Machine Building & General Manufacturing

SCADA & production data

OEE measured on 14 machines and raised from 58.1 % to 67.0 % once downtime reasons were coded at the machine.

OEE · %

67.0

Availability · %

Read project record →

Context

Industries and platforms

Context

Industries and platforms

Industries

IND-01

Automotive & Mobility

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IND-01

Automotive & Mobility

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IND-02

Food & Beverage

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IND-02

Food & Beverage

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IND-03

Packaging & Consumer Goods

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IND-03

Packaging & Consumer Goods

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IND-08

Machine Building & General Manufacturing

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IND-08

Machine Building & General Manufacturing

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Technology ecosystem

IIoT / Edge

TEC-13

OPC UA & MQTT

Vendor-neutral machine connectivity through edge gateways, with buffering and a defined IT/OT boundary.

OPC UA · MQTT · Sparkplug B

Integrates With

HMI / SCADA

TEC-12

Ignition by Inductive Automation

SCADA, HMI and production-data applications built on Ignition, including OEE and downtime reporting.

OPC UA · MQTT · SQL

Experience

PLC / PAC

TEC-01

Siemens SIMATIC S7-1500 / TIA Portal

PLC and safety-PLC programming, TIA Portal migrations from legacy S7 and S5 platforms, PROFINET network design.

PROFINET · PROFIsafe · OPC UA

Experience

PLC / PAC

TEC-02

Rockwell Automation Allen-Bradley ControlLogix / CompactLogix

ControlLogix and CompactLogix control and safety programs, PLC-5 and SLC 500 migrations, FactoryTalk integration.

EtherNet/IP · CIP Safety

Experience

Resources

Technical notes

Resources

Technical notes

Application Note

Inline data matrix reading for part traceability

Machine vision

Application note · 6 min read

Apr 15, 2026

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Inline data matrix reading for part traceability

Machine vision

Read

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Insight

Why OEE data needs reason codes before dashboards

Production data

Article · 5 min read

Feb 11, 2026

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Why OEE data needs reason codes before dashboards

Production data

Read

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An engineer replies within one business day.