Industry without data is like sailing blind
An industrial park without digital monitoring means machines that break down unexpectedly, unplanned production line stoppages, high corrective maintenance costs, and no visibility into actual productivity.
Monitoring industrial equipment provides the missing visibility:
- All machines in a single dashboard — status, metrics, trends.
- Immediate alerts when equipment deteriorates or fails.
- Complete history to analyze recurring failures and optimize maintenance.
- Real-time OEE to monitor production performance.
- Remote access for diagnostics and remote maintenance without on-site visits.
Industrial Supervisory Architecture
Industrial KPIs Monitored in Real Time
| KPI | Source Data | Calculation |
|---|---|---|
| Availability (%) | Machine status (Modbus register) | Run time / Open time |
| Performance (%) | Parts counter, cycle time | (Parts × Theoretical Cycle Time) / Open Time |
| Quality (%) | Scrap Counter | 1 - (Scrap / Total Parts) |
| OEE (%) | The 3 above | Uptime × Performance × Quality |
| MTBF (h) | Failure History | Total Time / Number of Failures |
| MTTR (h) | Repair History | Total Repair Time / Number of Failures |
| Energy Consumption | Energy Meter | kWh per Part Produced |
Anomaly Detection and Predictive Maintenance
Continuous monitoring generates a normal signature for each machine (temperature, current, vibration at rated conditions). An anomaly detection algorithm flags gradual deviations:
- Motor temperature increasing by 2 °C per week → monitor the bearing.
- Motor current deviating by 15% from the rated value → abnormal mechanical load.
- Cycle time gradually increasing → tool or process degradation.
- Number of defects per hour increasing → equipment nearing end of life.
These indicators make it possible to plan preventive maintenance before a breakdown occurs, rather than reacting to an emergency.
Use Case: Monitoring a Production Line
A production line with 12 Schneider M340 PLCs, 8 Danfoss drives, and 3 energy meters is connected via a shared RS-485 Modbus bus. The Eziwan gateway reads all the devices and uploads the data to the cloud every 30 seconds.
Benefits observed:
- OEE displayed in real time on the shop floor (synoptic display) and accessible from team leaders’ smartphones.
- 40% reduction in unplanned downtime thanks to early warnings.
- 60% reduction in maintenance trips thanks to remote diagnostics.
- Monthly production report generated automatically.
The Eziwan Approach
The Eziwan Gateway connects to the shop floor’s RS-485 bus or Ethernet network, reads data from equipment via Modbus RTU/TCP or OPC UA, and sends the data to the Eziwan Cloud. Configure KPIs, alert thresholds, and dashboards in just a few minutes via the cloud interface.
For more information: industrial remote maintenance, Modbus Cloud, and industrial maintenance alerts.