Machine Monitoring Software for New and Older Machines

Real-time machine monitoring software

Once a machine is connected, Fabrico shows what it is doing right now. Everyone from the shift lead to maintenance sees the same live data, on a wall screen in the hall or on a phone.

Machine status: which machines are running and which are stopped, line by line.

Counts: cycles from the machine signal, or parts counted by the camera, per machine and per shift.

Stops and micro-stops: each stop with its start time and length, down to the short stops too brief to log by hand.

Machine timeline: a colored bar per machine shows when it ran and when it stopped, shift by shift.

Live OEE: availability, performance and quality for each machine, updated as new data comes in.

A shift lead sees a stopped machine while the stop is still going on, not in the next morning's report. That leaves time to act during the shift where the loss happens.

It is all one platform. The same stops show up by cause and by machine in the downtime tracking software view, and the OEE figures roll up into shift, line and plant reports in the OEE software.

To see what the gap between your current and target OEE is worth, use the OEE calculator.

PLCs on automated machines

Automated machines usually run on a PLC or another control system. Fabrico reads the control signals, such as cycle start, stop and downtime events, so each cycle and each stop arrives with a timestamp and nobody has to write it down.

Your own automation team, a partner you work with, or the Fabrico team can do the integration.

IoT sensors for legacy machines

Older and semi-automated machines often have no PLC to read. For these, the Fabrico team can install an IoT device with external sensors, such as an optical sensor that detects each cycle.

The device reports each cycle to Fabrico as it happens, so an older machine also shows its status, counts and stops on screen, next to the newer machines on the line.

AI cameras for manual lines

Some stations give no machine signal at all, such as manual assembly or packing. There, AI cameras recognize and count output, so these stations get counts too.

The camera counts land on the same timeline as the PLC and sensor data. Our computer vision page covers the cameras in more detail.

A plant can mix all three paths, and every connected machine shows up in the same OEE view.

Shop floor data collection

Connected machines report their own status, cycles and stops. What no signal carries, operators add on a tablet at the machine instead of on a paper sheet.

Reason codes: the operator tags each stop with its cause from a list your team sets up, so every shift uses the same causes.

Counts and scrap: operators enter good parts and scrap where no sensor counts them, so the quality figure in OEE uses the counts they record.

QR codes on machines: scanning the code on a machine opens that machine in the app, so the entry is tied to that machine.

Tablet, phone or browser: the same app runs on iOS, Android and the web, in English, German, French, Polish and Bulgarian, and other languages can be added.

Paper sheets get filled in after the fact, from memory, and someone types them up at the end of the day. A tablet entry is made at the stop, with the machine and the time already attached.

ERP, API and built-in CMMS

Machine data sits next to maintenance in Fabrico, and Fabrico connects to the other systems you run:

Maintenance (CMMS): when a machine breaks down, a technician opens a work order from the stop. Fabrico tracks the reaction time, and each repair counts toward that machine's MTTR and MTBF.

Machine records: each machine has one record with its files and its repair history.

ERP: two-way sync with SAP PM, integration with SAP S/4HANA, and custom integration for Dynamics, Oracle and other ERPs.

REST API and webhooks: for your own systems and reports, plus Zapier for other cloud tools.

Excel and CSV export: any list goes out to Excel, and CSV export is available too.

Multi-plant machine monitoring

With a group account, each plant keeps its own view and head office sees all of them together. Cross-plant reports compare machines and lines between sites.

Dashboards are set up for your company as a whole, so each plant reads OEE in the same way.

Role-based access decides who sees what, and single sign-on through SAML can be added as a custom integration. An audit log keeps a record of changes.