Downtime without context
The production stop is recorded, but the preceding states and signal changes are no longer available in one place.
Downtime Analysis for Production
Do not just count downtime. Understand what happened before.
PlantWatch reconstructs which machine states, warnings, and process values changed before a production stop. This turns a single downtime timestamp into a traceable event sequence.
- Existing PLC data
- Read-only Monitoring
- On-Premise
PlantWatch is typically connected as a monitoring layer. The specific technical implementation is assessed based on the existing controllers and interfaces.
The downtime is visible. The trigger often is not.
A timestamp alone does not explain a production stop.
Many systems document when a plant stopped. The technical investigation often lacks context: Which load increased? Which signal was lost? Which interlock became active? And in what sequence did it happen?
A conventional downtime log records when production stopped and how long it remained stopped. PlantWatch also shows which relevant signals and machine states changed beforehand and in which sequence.
Scattered information
Alarms are stored in the HMI, process values in the PLC, and additional clues in shift logs or spreadsheets.
Repeated investigation
Every similar stop triggers a new reconstruction, often with incomplete data and from memory.
One stop. Eight seconds of history.
The complete sequence—not just the final alarm.
PlantWatch arranges relevant state changes over time. This makes it possible to review what happened immediately before the stop and which events repeatedly occur in the same sequence.
Signal lanes
- Conveyor loadRising
- Sensor S-14Signal lost
- InterlockActive
- ProductionStopped
Event sequence
- Conveyor load risesT+0 s
- Sensor signal S-14 lost+5 s
- Interlock activated+1 s
- Production stopped+2 s
Simplified example. Available events and time resolution depend on the connected data sources.
Control data becomes investigation context
What becomes visible together during downtime.
PlantWatch connects downtime duration, machine states, warnings, and process values into a traceable event sequence—based on data your controllers already capture.
Start and duration
PlantWatch records when downtime began, how long it lasted, and when production resumed.
States and signals
Machine states, interlocks, alarms, counters, and relevant process values are shown in their temporal context.
Event sequence
Changes before and during the stop can be reviewed as a chronological sequence.
Recurring patterns
Similar events can be compared across shifts and production periods.
From signal to technical investigation
A shared data basis for production and maintenance.
- 01
Collect data
PlantWatch reads relevant production signals through existing industrial interfaces.
- 02
Store over time
States, warnings, and process values are stored with timestamps in a continuous history.
- 03
Bring events together
Signal changes and machine states around the stop are presented in one shared view.
- 04
Compare sequences
Teams can investigate individual stops and compare recurring sequences across different periods.
Before and with PlantWatch
Less reconstruction from separate sources.
Separate sources
Without a shared history
- 01Search alarm archives individually
- 02Ask shift personnel to reconstruct the sequence
- 03Collect process values from different systems
- 04Align timestamps manually
- 05Investigate recurring stops again from the beginning
Shared history
With PlantWatch
- 01Open the stop and its relevant history together
- 02Compare signals and machine states over time
- 03Review process values around the event
- 04Find similar events across production periods
- 05Discuss findings using a shared data basis
Questions from production operations
Which question should the available data help answer?
Which signal changed first?
Which interlock was active before the stop?
Which process values changed immediately beforehand?
Did the same event sequence occur during another shift?
How long did comparable stops last?
At which machine or plant zone did the sequence begin?
Which questions can actually be answered depends on the available control data, timestamps, and connected production areas.
Built on existing control data
Downtime analysis without replacing the existing plant.
PlantWatch operates as an additional monitoring and analysis layer alongside existing PLC, HMI, and SCADA systems. The machine controller remains responsible for the production sequence.
For technical background on connectivity, see OPC UA in production.
PLCs and machines
PlantWatch
History, event sequences, and reports
Typical interfaces
- OPC UA
- Siemens S7
- Modbus TCP
- Existing databases or APIs
Normally not required
- No PLC replacement
- No new HMI
- No SCADA migration
- No mandatory cloud connection
The most suitable technical connection is assessed based on the installed controllers, available interfaces, and network structure.
Technical fit
When is a plant suitable for PlantWatch?
Relevant data is available
The PLC or an existing system provides machine states, alarms, counters, or process values.
The data is reachable
Controlled network access can be provided for the selected controllers or interfaces.
The investigation question is defined
The initial production area and type of downtime to investigate are clearly defined.
FAQ
Questions about downtime analysis with PlantWatch
Technical requirements and the limits of analysis.
Does PlantWatch automatically identify the cause of downtime?
PlantWatch presents relevant signal changes, machine states, and process values in their temporal context. This data supports the technical investigation. Whether a definitive cause can be derived depends on the process and the available signals.
Do operators need to enter downtime reasons manually?
Downtime timestamps and available state changes can be captured from connected control data. Manual additions can still be useful when organizational causes or events not captured technically need to be documented.
Does PlantWatch write data back to the PLC?
PlantWatch is typically connected as a monitoring layer. It reads relevant production signals without changing the machine sequence or control logic.
Do we need OPC UA?
Not necessarily. Depending on the existing environment, PlantWatch can connect through OPC UA, Siemens S7, Modbus TCP, databases, or existing APIs.
Can we start with a single machine?
Yes. An initial implementation can be limited to one machine, line, or clearly defined production area.
Where is the data stored?
PlantWatch runs on premises. The captured production data remains within the provided infrastructure and does not need to be transferred to an external cloud platform.
Downtime analysis with existing data
Find out which sequences your controllers can already make visible.
We review the existing controllers, interfaces, and production questions. You then receive a clear assessment of whether and how PlantWatch can be connected.