One unplanned downtime loss far exceeds monitoring investment
A sudden key equipment outage on the production line costs an entire shift's output and delivery deadlines.
Product Solution 05 / 08
Factory Equipment Monitoring & Alerting System
Online monitoring of production line electromechanical equipment, early warning before abnormal downtime to reduce unplanned outage losses
Solution Overview
Online monitoring of factory electromechanical equipment, collecting temperature, vibration, and operational status, identifying abnormal downtime with early warnings to reduce unplanned outage losses.
Discrete manufacturing workshopsInjection molding and metalworking linesPackaging and conveyor linesUtility equipmentSmall pump stations and dust removal equipment
Problems Solved
Equipment status judged by experienced technicians listening to sounds
Experience is hard to replicate and institutionalize. When personnel turnover occurs, on-site diagnostic capability drops directly.
Alerts disconnected from maintenance
Knowing there's an anomaly but no one dispatched, or lacking processing records — the same problem recurs repeatedly.
Key Features
Key equipment online monitoring
Collect temperature, vibration, current, and run/stop status per equipment registry into a unified view.
Pre-failure sign identification
Compare against historical normal operating characteristics; identify abnormal temperature rise, increasing vibration, and abnormal start-stop frequency.
Downtime event recording
Automatically record downtime timing, duration, and associated alerts; output downtime statistics.
Alerts push directly to responsible person
Push to WeCom or SMS per workshop/team; automatically escalate if unacknowledged beyond timeout.
Alert-to-work-order conversion
One-click generation of repair work orders; processing steps and replaced parts documented into equipment health records.
Data Collection & Alerting Specs
Collected Data
- Equipment run/stop status
- Bearing and housing temperature
- Vibration values
- Current and power (optional)
- Start-stop count and runtime
Alert Types
- Unplanned downtime
- Persistent elevated temperature
- Vibration exceeding limit or rising trend
- Device offline
- Alert unacknowledged timeout
Alerts pushed to Web dashboard and WeCom; SMS as optional add-on. Same-type alerts auto-merged for noise reduction.
Deployment & Billing
- Deployment
- Collect existing sensor signals via on-site DTU; surface-mount vibration-temperature sensors can also be added. No production stoppage during installation — single-point modification typically completed within the shift.
- Billing
- Priced by combination of device count and point count; supports pilot on 1–3 key devices first.
- Related Scenarios
- 工业制造场景
FAQ
Legacy equipment has no signal output — can it still be monitored?
Yes. A common approach is to mount external temperature and vibration probes on bearing housings and casings, aggregated and reported via DTU — no modification to equipment body or control cabinet logic needed.
Will there be many false alarms?
The platform first establishes a baseline for each device from normal operating data, then combines trend analysis and delayed confirmation for determination. Same-type alerts are auto-merged and classified as urgent/normal to avoid notification flooding.
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Factory Equipment Monitor｜Request Demo & Quote
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