OEE & Downtime Analytics
Availability × Performance × Quality per machine, line and shift, computed from PLC status and stop reasons. Loss trees that tell you what to fix first.
Plant Digitalization suite
Which machines are ON. Why the others stopped.
Read machine status straight from the PLC, capture the reason behind every stop, retire paper check sheets and generate every report from one source of truth. Modular, white-labelled with your plant's identity, and live on any device within weeks.
Machine ON/OFFLive status for every machine
Why it stoppedReason tagged by the operator
PLC integrationSiemens, Mitsubishi, Allen-Bradley, Delta…
PaperlessCheck sheets on tablets with approvals
Reports with approval flowPrepare → review → approve, audited
White-labelledYour name, logo and colours
Centralized Machine Monitoring System
Every machine, every plant, one live board
Tracium integrates with the machine's PLC and reports ON, IDLE or STOPPED the moment the state changes. When a machine stops, the operator picks the reason on the tablet. The plant wall board, the supervisor's phone and the MD's laptop all show the same truth, with no manual logging.
- Machine ON/OFF status, read directly from the PLC
- Why it stopped: die change, no material, breakdown, quality hold, break, with time per reason
- Cycle counts, parts produced and target-vs-actual per shift and per machine
- Multi-plant roll-up: compare lines, plants and shifts side by side
- Instant alert when a machine stops longer than its allowed time
Press Shop · Shift ALIVE
ON 5Idle 2Stopped 1 · Die change
Why it stopped
Every stop gets a reason, every reason gets a number
The PLC tells us a machine stopped. The operator tells us why, in two taps. By the end of the shift you know exactly how many minutes went to die changes, material shortages, breakdowns and breaks, per machine, per shift, per operator.
- Reason codes configured per machine type, grouped as planned vs unplanned
- Operator tags the reason on the tablet or andon button; untagged stops are escalated
- Pareto of stop reasons by machine, line, shift and month
- Feeds OEE availability and the preventive-maintenance schedule automatically
| Stopped at | Duration | Reason | Tagged by |
|---|---|---|---|
| 06:42 | 22 min | Die change | R. Kumar |
| 08:15 | 9 min | No material | R. Kumar |
| 10:30 | 10 min | Tea break | Auto (schedule) |
| 11:58 | 4 min | Untagged | Escalated |
Die changeNo materialBreakUntagged
Digital CheckSheets
Paper check sheets, retired for good
Start-up, in-process, quality, safety, 5S and maintenance check sheets become tablet forms with the right fields, the right tolerances and the right approver. Nothing gets lost, back-dated or skipped.
- Form designer: numeric, pass/fail, photo, signature, dropdown and formula fields
- Scheduled per shift, per machine, per product change-over
- Multi-level approval with escalation when a sheet is overdue
- Out-of-tolerance values raise alerts and block the next step if required
- Print-ready PDF for audits, with full edit history
| Check point | Spec | Reading | Result |
|---|---|---|---|
| Hydraulic pressure | 100–120 bar | 110 | OK |
| Oil temperature | < 55 °C | 48 | OK |
| Safety light curtain | Functional | Yes | OK |
| Die alignment | ± 0.05 mm | 0.08 | NG |
| First-piece inspection | Photo | 📷 attached | Pending |
Operator: R. Kumar · 06:12 · Awaiting supervisor approval
Approve
Reporting with approval flow
One report hub, every report approved before it counts
Every production, stoppage, quality and maintenance report in one catalogue, filled automatically from machines and check sheets, or by upload and screen entry where data is still manual. Each report then moves through a configurable approval flow: the operator prepares, the supervisor reviews, the plant head approves, with comments, rejections and a full audit trail at every step.
- Maker-checker-approver flow per report, with one or many approval levels
- Reviewers can comment, send back or approve from phone or laptop; overdue approvals escalate
- Locked after approval; every edit before that is versioned and attributed
- Excel upload and tablet entry for reports that are not yet automated
- Drill-down dashboards and scheduled e-mail / WhatsApp delivery of approved reports
| Line | Target | Actual | Stops | OEE |
|---|---|---|---|---|
| Press Line 1 | 4,800 | 4,710 | 38 min | 86% |
| Press Line 2 | 4,800 | 4,120 | 61 min | 74% |
| CNC Cell | 1,200 | 1,215 | 9 min | 91% |
| Assembly | 3,000 | 2,980 | 12 min | 88% |
✓ Prepared · R. Kumar→✓ Reviewed · Supervisor→● Awaiting approval · Plant head
More modules
Grow module by module
All modules share machines, users, shifts and products, so each one you add makes the others smarter.
Andon & Alerts
Operator call buttons for maintenance, material and quality. Andon boards, TV displays and WhatsApp / SMS / e-mail escalation when response time is breached.
Maintenance Management
Preventive schedules triggered by real run-hours or cycle counts from the PLC, breakdown logging with MTBF / MTTR, spares and technician work orders.
Quality & SPC
In-process inspection, X-bar / R charts, Cp / Cpk, rejection analysis by reason and operator, and hold / release of lots.
Production Planning
Shift-wise plans by machine and product, change-over tracking, live plan-vs-actual, and automatic re-planning when a machine stops.
Users, Shifts & Roles
Operators, supervisors, plant heads and management, each with their own screens. Shift calendars, handover notes and a full audit trail of who did what.
Deployment
From site survey to live board in weeks
A typical first plant: survey the machines and their PLCs, integrate, configure lines and shifts, train operators, go live. Then add modules.
- Week 1 · Survey & designMachine list, PLC makes and models, network, shift and product master data.
- Week 2–3 · IntegrateConnect each PLC, verify ON/OFF status for every machine on the live board.
- Week 3–4 · Configure & trainStop reasons, check sheets, reports, alerts and user roles. Operator and supervisor training on the floor.
- Go-live & beyondHyper-care for the first shifts, then monthly reviews to add the next module.
Machines
Siemens PLC
Mitsubishi PLC
Allen-Bradley PLC
Operator tablets
PLC integration · OPC-UA · Modbus · MQTT
Tracium Plant platform
Machine ON/OFF
Stop reasons
CheckSheets
Report hub
OEE engine
Andon & alerts
Maintenance
Users & roles
Cloud · On-premise · Hybrid
Consumers
Wall-board TVs
Supervisor phones
Management dashboards
ERP / MES
FAQ
Common questions
Which PLCs can you integrate with?
Siemens, Mitsubishi, Allen-Bradley, Delta, Omron and most others, over OPC-UA, Modbus TCP or the vendor's native protocol. We confirm the exact method for each machine during the site survey.
How does the system know why a machine stopped?
The PLC reports the stop; the operator picks the reason on the tablet or andon button from a list configured for that machine. Scheduled breaks are tagged automatically, and any stop left untagged is escalated to the supervisor.
Does the system need internet on the shop floor?
The platform can run on an on-premise server, so the live board keeps working even if the internet link drops. Cloud sync resumes automatically.
Can we keep some reports in Excel?
Yes. The report hub accepts Excel uploads and screen entry on tablets for reports that are still manual, and migrates them to automated feeds one at a time.
How is it licensed?
Per plant, per module, with the number of machines and users. Start with machine monitoring or check sheets and add modules as you go.
See a live machine board for your plant
Share your machine list and PLC makes. We'll connect one machine and show it live on a wall board in the same visit.