Manufacturing & Automation
Machine monitoring and data collection for manufacturing
Machine information is not new to manufacturing. SCADA systems have been available for years, but they're typically expensive, complex to set up, and don't easily enable collecting historical data from multiple sources in one place. ExoSense® can transform manufacturing into Industry 4.0 with cloud-based machine data collection, alongside or as a simplified approach to SCADA.
Industry 4.0 has moved to baseline
Manufacturers are running industrial IoT at scale, not only piloting it, and most are doing it to enhance existing lines rather than rip out SCADA. ExoSense gives that data a home without a rebuild, pairing naturally with predictive maintenance once the data's flowing.
With Exosite
- 1Connect
Pull data from the line
PLCs, SCADA systems, and connected sensors on the line.
- 2Digitize
Normalize machine data
ExoSense maps data from every source into consistent signals.
- 3Detect
Spot drift in real time
Streaming analytics flag anomalies, outliers, and drifting performance.
- 4Act
Fix it off-peak
Teams get the alert, find the root cause, and schedule maintenance during off-peak hours.
Key features
Aggregated data
Real-time machine data for OEE, runtime, uptime, energy use, and maintenance planning.
Legacy equipment
Connect existing SCADA systems, PLCs, and controls, or add sensors to older equipment.
Analytics
Streaming analytics and machine learning find anomalies and performance outliers before they cause downtime.
OEE, runtime, and uptime from your machine data
Most lines already produce the signals needed to measure performance: run and stop states, cycle or part counts, and reject counts from PLCs and controllers. ExoSense turns them into runtime, uptime, and Overall Equipment Effectiveness (OEE) with transforms in the data pipeline, without adding a separate OEE system.
- Availability
- Runtime against planned production time, with downtime logged by machine.
- Performance
- Actual cycle rate against the ideal rate for each machine.
- Quality
- Good parts as a share of total parts produced.
The same numbers feed dashboards, shift and weekly reports, and alerts, for example when a line's availability drops below target. Trends over time tie directly into lean and continuous improvement work.
Predict and plan maintenance
ExoSense provides historical trends and machine health alerts, so technicians can identify potential issues, pre-order parts, and schedule maintenance during off-peak hours instead of stopping the line unexpectedly. Energy use, usage, and runtime data also show where equipment is running inefficiently.
Diagnose systemic problems
Although it's important to receive alerts on failing equipment, ExoSense can also provide historical data to help technicians diagnose and prevent further issues: temperature and electrical line charts, runtime data, and high-resolution vibration frequencies gathered over time.
Hastings provides high value, quality engineered, energy efficient and environmentally responsible industrial air filtration systems, product and service solutions that protect workers from harmful airborne contaminants.
Read the story →Kadant
Kadant needed to expand their Condition Based Maintenance (CBM) services with connected product lines to help increase service contract lifetime values and drive replacement parts revenues.
Where your program can go next
Most teams start with one line, one cell, or one machine type. The same connected equipment then supports predictive maintenance across the plant, service agreements for the machines you sell, and connected products if you build automation equipment.
- Condition MonitoringReal-time equipment health, alerts, and dashboards for your customers.
- Predictive MaintenanceAnomaly detection and machine learning in the data pipeline to catch failures early.
- Service TransformationMove from selling equipment to selling uptime and recurring service.
- OEM Connected ProductsConnect your product for usage data, field feedback, and over-the-air updates.
Ready to see if we're the right fit?
Connect with an expert to see how Exosite's IoT solutions can accelerate your connected-product success.