One live picture of the whole plant.

The challenge

A mid-sized plant runs machines from several decades. Some have modern controllers that expose their data; others only have analogue gauges. Performance is reviewed from paper logs at the end of each shift, and breakdowns come as a surprise.

Plant Pulse connects old and new equipment into one live view, so managers see performance as it happens and maintenance moves from reactive to planned.

What the system does

1. 01

   Collects data from controllers, sensors and retrofitted devices over OPC UA, Modbus and MQTT.

2. 02

   Maps every machine into a single asset model, a digital twin of the plant, with its live state and history.

3. 03

   Calculates availability, performance and quality (OEE) for each line in real time.

4. 04

   Detects unusual vibration and temperature patterns and raises a maintenance alert before a failure.