Designed for high mix and high volume plants
Capture cycles, idles, stops, and production context such as job and part IDs so performance metrics remain accurate across SKUs, changeovers, shifts, and varying operating patterns.
Real time machine monitoring
Rayterton IoT Manufacturing Monitoring System
Real time visibility from machine to enterprise. Connect PLC, SCADA, and IIoT sources, stream telemetry, compute OEE, track downtime and micro stops, monitor SPC and energy metrics, automate alarms and escalations, run digital workboards, and enable predictive analytics with historian and data lake feeds. Integrated with MES, CMMS or EAM, QMS, and ERP.
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100 percent risk free, no upfront payment or long term contract commitment
Key domains covered
Monitoring Suite
Connectivity, OEE, Quality
- Connectivity and edge buffering for trusted signals
- OEE, losses, downtime, and micro stop tracking
- Andon alerts, escalations, and digital workboards
- Historian, BI feeds, and predictive analytics
Unified monitoring layer
Single Platform for Machine Visibility and Operational Control
Rayterton IoT Manufacturing Monitoring System connects machine signals, production context, and operational KPIs in one place. Operations, maintenance, and quality teams see the same truth in real time instead of waiting for manual reports.
Standardised yet highly configurable
Start with standard OEE and loss models while allowing configuration for tag mappings, downtime taxonomies, thresholds, escalation rules, and KPI definitions. Scale from one line to multi plant rollouts with governance on devices and data quality.
Connectivity and data capture
Connectivity and Data Capture Foundation
A strong connectivity and edge layer ensures production signals are captured reliably, buffered during network issues, and enriched with context for meaningful analytics.
Connectivity and edge gateway
OPC UA or DA, Modbus, MQTT, and REST with edge buffering and local logic for resilient data collection.
Data collection and context
Tags, counters, cycle and idle states, job and part IDs, and operator input terminals to link signals to real production activity.
Security and governance
TLS, RBAC or SSO, and audit logs so plant monitoring aligns with corporate security and compliance requirements.
Device inventory and health
Maintain device lists, tag catalogs, configuration versions, and patch status to keep deployments controlled and auditable.
Performance and losses
OEE, Loss Analysis, and Downtime Management
Turn raw telemetry into actionable performance insight. Standardise how OEE and losses are calculated so teams can compare lines fairly and target the highest impact improvements.
OEE and losses
Availability, performance, and quality with Six Big Losses, micro stops, and changeover tracking.
Downtime tracking
Automatic detection with manual reason codes, Pareto analysis, and links to MTBF and MTTR improvement loops.
Digital workboards
Cell and line dashboards with target vs actual, status lights, and KPI scoreboards for daily execution.
Shift and performance reviews
Shift summaries and exception views that support stand up meetings, loss elimination, and continuous improvement routines.
Alerts and response
Andon, Alerts, and Escalation Workflows
Reduce response time by turning abnormalities into clear notifications with defined ownership and escalation rules that prevent prolonged downtime and recurring micro stops.
Andon and alerts
Rule based alarms, call for help, escalation paths, and a notification center for supervisors, maintenance, and quality.
Escalation policies
Multi level escalation by severity and time thresholds to ensure issues do not linger on the floor.
Response traceability
Track when alerts were raised, acknowledged, resolved, and what corrective action was taken.
Connected workflows
Integrate alerts with CMMS work orders and QMS events so actions are recorded and auditable.
Quality signals
SPC, Quality Signals, and Traceability Readiness
Bring quality signals closer to the shop floor with statistical monitoring and automated handoffs to quality processes, reducing escapes and improving response consistency.
SPC monitoring
X bar and R, p or np, c or u charts with rule violation detection and exception views.
Quality event linkage
Route violations and defects to CAPA and QMS workflows with supporting evidence from machine and operator data.
In process checkpoints
Combine sensor readings, operator checks, and sampling results to detect drift before escapes occur.
Traceable evidence
Maintain a clear trail from machine data to quality actions for audits and customer requirements.
Energy and sustainability
Energy, Sustainability, and Cost per Unit KPIs
Track energy and environmental metrics alongside output to reduce cost per unit and support sustainability targets across lines, shifts, and SKUs.
Energy monitoring
kWh, compressed air, water, emissions, and energy per unit KPIs by line, shift, and SKU.
Performance correlation
Link energy spikes to downtime, micro stops, speed losses, and changeovers to target true causes.
Baselines and targets
Set baselines and targets by asset or process and monitor drift with alerts and exception views.
Reporting readiness
Provide structured data for operational energy reviews and sustainability reporting workflows.
Analytics ready monitoring
Predictive Analytics and Historian Data Platform
Move beyond dashboards with time series foundations and early warning signals that help reduce breakdowns and unplanned stops, while enabling deeper BI and data science use cases.
Predictive analytics
Anomaly detection, degradation trends, and failure prediction based on equipment behavior patterns.
Historian and data lake
High resolution time series retention with controlled access for BI, analytics, and data science workloads.
Pattern discovery
Identify recurring losses, abnormal cycles, and early warning patterns across assets and lines.
Scalable data architecture
Support multi plant analytics with consistent tag standards, naming conventions, and governance.
Technology and integration
Integration and Technology Choices
Monitoring is designed to connect with execution, maintenance, quality, and enterprise systems so plant signals drive action, not just visibility.
Integration with manufacturing systems
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Connect to PLC, SCADA, and IIoT sources using OPC UA or DA, Modbus, MQTT, or REST.
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Integrate with MES for orders, SFC, production context, and execution status.
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Integrate with CMMS or EAM for work orders, maintenance events, and improvement loop visibility.
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Integrate with QMS for CAPA, nonconformance, and quality workflows linked to SPC signals.
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Feed historian data to data warehouse or BI platforms for executive dashboards and deeper analytics.
Security, access, and deployment
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Role based access and single sign on options aligned with corporate standards.
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TLS transport, audit logs, and device governance for controlled rollouts.
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Support for on prem, edge, cloud, or hybrid deployment depending on plant policy.
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Scalable architecture ready for rollout across lines, plants, and business units.
Engagement model
What You Get From Rayterton
Implementation approach follows the same pattern as other Rayterton solutions. The focus is a working monitoring environment connected to your lines and configured to your losses before you make any commercial commitment.
Before go live
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Free customisation for KPIs, OEE models, downtime taxonomy, alerts, and digital workboards your team needs.
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Working trial environment connected to selected PLCs and signals with edge buffering and baseline dashboards.
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Support to configure device inventory, tag mappings, thresholds, escalation rules, and pilot integrations.
After go live
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Annual maintenance that already includes change requests without extra manday cost.
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Monitoring and performance tuning for ingestion, dashboards, historian storage, and integrations when required.
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Optional deeper integration with MES, CMMS or EAM, QMS, ERP Manufacturing, and Data Warehouse or BI.
Ready to make every machine visible and every loss actionable
Share your lines, PLC types, top downtime reasons, and improvement priorities. The Rayterton team will prepare a prototype monitoring environment with OEE, downtime tracking, digital workboards, and alert escalations so operations, maintenance, and quality teams can validate impact together.
Rayterton can start the project without any upfront payment and without long term contracts. The focus is to make sure the solution fits
and successfully goes live first.