For reference only: The chart shows common patterns seen across heavy industry.
Your plant’s numbers will look different — and that’s the point. With PlantWatch you’ll see real-time evidence from your own machines, so decisions are based on facts, not averages.
How Sync PlantWatch Turns Signals into Insights
All without changing your PLC logic
01
Tap the signals, not the controls.
We attach a read-only tap to your existing PLCs—air-gapped by default, no writes, no logic changes.
02
One clean view of mixed vendors.
We normalize tags across OPC UA / S7 / EtherNet/IP (CIP) / Modbus into a single, consistent namespace.
03
Real-time monitoring that keeps running.
Live KPIs and events turn into a Downtime Map and AI-driven insights you can act on immediately.
What You Get, From Day One
Your plant’s data, mapped and explained — within 30 days.
Real-Time Monitoring & Historian
See stoppages and slowdowns as they happen.
A live monitoring layer and built-in historian keep recording from day one — so you don’t just get a snapshot, you get a timeline of evidence you can always go back to.
Downtime Map + Root-Cause Traces
Find the biggest leaks in hours, not months.
Pareto analysis highlights your top downtime drivers. Each stoppage is logged with traces so you can see patterns — like repeated faults, shift-specific stoppages, or equipment that drags the whole line down.
CSV/DB Export That Stays
Keep your data, even if you stop.
Every datapoint we collect can be exported as CSV or fed into your existing DB. That access doesn’t go away when the trial ends — you keep the files and the historian running locally.
Site Briefing With Next Steps
Turn raw data into an action plan.
At the end of the trial, we walk your team through the findings, rank your biggest loss drivers, and map practical next steps for modernization or maintenance priorities.
Safety & Security — Plant-Safe by Design
Read‒only. Air‒gapped. No control risk.
We build PlantWatch under the strictest cybersecurity guidelines you can imagine. Every connection is read-only, every transfer is one-way, and every action is logged. By default, the system is air-gapped, hardened on-prem, and never writes into your controls. This isn’t an add-on or afterthought — security is built in by design, so operators and IT alike can trust that visibility comes with zero production risk.
PLC Families Supported
Siemens
SIMATIC S7-300, S7-400, S7-1200, S7-1500
Rockwell / Allen-Bradley
Micro800, MicroLogix, CompactLogix, ControlLogix
Beckhoff
EtherCAT-based PLCs
Others on Request
We’ve worked across Schneider, Mitsubishi, ABB, GE and more. If your PLC isn’t listed, we’ll confirm compatibility in a short discovery call.
Protocols Supported
OPC-UA / DA
Covers both modern UA and classic DA — unifies tags into one clean namespace.
EtherNet/IP (CIP)
One of the most widely used industrial protocols, supported by Rockwell, Siemens, and others.
Modbus (TCP / RTU)
Still the backbone of many plants — we support both serial and TCP variants.
Others on Request
We also support additional industrial protocols — confirmable in a short discovery call.
#connect
Industries We Serve
Above-ground operations welcome. Brownfield first.
We focus on above-ground industries where downtime directly hits throughput. From mining and cement to bulk handling and processing, Sync Motion delivers clarity without control risk — even in brownfield sites running legacy systems.
Mining & Aggregates / Quarries
From gravel pits to large stone operations — throughput made predictable.
Cement &
Asphalt
Continuous plants gain faster root-cause detection and less downtime.
Lumber &
Sawmills
From saw lines to kilns — keep production flowing with real-time monitoring of legacy controls.
Materials Processing
Legacy automation modernized with read-only taps and unified monitoring.
Reduce Unplanned Maintenance
Stop reacting to breakdowns in crisis mode. With clear traces and timelines, you move from firefighting toward predictable planning that saves time and stress.
Boost
Throughput
Every minute of uptime counts. By eliminating recurring stoppages, your plant delivers more tons per shift without investing in new equipment or longer hours.
Fewer “Mystery”
Halts
Operators no longer face unexplained shutdowns. Evidence-backed traces explain why lines stop, so issues are solved quickly and permanently.
Budget
Smarter
Hard data shows which parts and upgrades actually impact costs. Investments stop being guesswork and start being clear, prioritized decisions.
Cut Recurring
Stoppages
We surface the real root causes behind repeated halts. Instead of chasing symptoms, your team fixes the biggest drivers first — reducing waste and unlocking more stable production.
From Flying Blind to Fact-Based in Weeks
A mining operation used Sync PlantWatch to uncover its top downtime drivers within the first month. By tapping existing PLCs, we mapped stoppages in hours and gave the team clear, evidence-based priorities.
Trusted Partners & Networks
Selected for Start.up! Germany Tour
Sync Motion was invited to the international Start.up! Germany Tour, a program showcasing young companies with practical solutions for industry. It gave us the chance to share our approach to modernizing brownfield operations with a wider audience.
We’re proud to collaborate
with leading clusters and innovation networks.
Through these networks, we take part in broader initiatives that bring together industry, innovation, and sustainability. They foster collaboration across companies, clusters, and institutions, strengthening the regional ecosystem we are proud to contribute to.
Straight Answers. No Surprises.
The most common questions from Ops, IT, and Finance—answered up front.
Ops: Will you touch our PLC logic?
No. Sync PlantWatch is read-only. We never write to your PLCs, never alter logic, and never change safety circuits.
IT: Can we keep data off the cloud?
Yes. Stage 1 is air-gapped by default. If you choose, Sync Knox provides a one-way feed into your on-prem IT (MES/ERP/BI). Cloud is optional in Stage 2, not required.
Finance: How is pricing handled?
We scope your site on a discovery call. Your baseline deposit is fully credited if you modernize later—so your initial outlay is risk-free.
After the trial?
You keep real-time monitoring, historian, and CSV/DB export running locally. Support and Sync Knox integration are optional add-ons, but your visibility doesn’t disappear.
Downtime impact during install?
Typical deployment fits within a short planned window (≤4 hours). We don’t change control logic, so there’s zero risk to production.
What if my PLCs are very old (e.g., S5)?
If you’re still running S5 or similar, that’s a clear signal it’s time to plan an upgrade. PlantWatch helps you bridge the gap safely: we can still tap into those legacy signals for monitoring today, while mapping a path toward modernization. We fully support S7-300/400, Rockwell legacy, Beckhoff, and mixed-vendor sites.
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