Signal survey
We walk the line and list what each machine can already tell us: PLC registers, counter outputs, proximity or photo sensors, or nothing yet.
Services Machine data & live dashboards
Machine data & live dashboards
Every machine,
counting for you.
We connect the machines you already run, whether new PLC-controlled or twenty years old, and bring their counts and status into one live view. No more chasing operators for numbers at the end of the shift.
When the numbers come too late.
Manual counts are slow, rounded and easy to dispute. Machine data is none of those things.
- Output is written up once a shift.By the time the register is tallied, the chance to recover the shift has gone.
- Nobody knows a machine stopped until someone walks past.Idle time hides in plain sight on a busy floor.
- Older machines have no data port.They still do most of the work, but they can’t tell you anything.
- Rejects are counted in a bin, not in a system.So quality problems surface as a heap at the end of the day.
What we connect and deliver.
Hardware, wiring, configuration and the dashboard, delivered by one team and validated against your own counts.
Retrofit sensing
For machines without usable outputs, we add sensors at the right point in the cycle to count strokes, parts or cycles reliably.
Good and reject counts
Separate good and reject signals where the process allows it, so quality is measured, not assumed.
Industrial gateways
Teltonika industrial routers and gateways collect the signals over Modbus or digital inputs and send them securely over MQTT.
Barcode and scanner points
Scanners at packing or inspection stations count units as they pass and record the codes for traceability.
Live dashboard
Counts, run/idle status and rates per machine, ready to feed the MES plan board and OEE when you are ready.
Connected in four steps.
We prove the data on a few machines before wiring the whole floor.
Plan a signal surveySurvey
Visit, photograph and list every machine’s available signals, panel space and network options.
Connect
Install sensors and gateways, wire the signals and configure what each one means.
Validate
Compare machine counts with your register for several shifts and fix any differences before going live.
Use
Put the dashboard in front of supervisors and on the shopfloor TV. Extend it to MES when the data is trusted.
Machines we commonly connect.
If a machine has a cycle, we can usually count it. The survey tells us how.
- Power pressesStroke and part counts
- CNC and VMC machinesCycle completion and status
- Injection mouldingShot counts and rejects
- Assembly and test stationsPass and fail outputs
- Packing linesScanned or sensed units
- Legacy machinesRetrofit sensors, no PLC needed
Questions we often hear.
Our machines are old. Can they still be connected?
Usually, yes. Where there is no PLC or data port, a sensor can count the machine’s cycle directly. The signal survey confirms the approach for each machine.
Do we need Wi-Fi across the shopfloor?
Not necessarily. Industrial gateways can use wired Ethernet or a cellular connection, depending on what is practical at each location.
Will this interfere with the machine’s controls?
No. We tap signals in read-only ways and do not change machine logic. Any electrical work follows your maintenance team’s approval.
How do we know the counts are right?
Before going live, we run the machine count side by side with your register for several shifts and resolve every difference.
Can we start with the dashboard and add MES later?
Yes. The same data feeds the MES plan board and OEE, so nothing is wasted when you extend.
Works alongside.
One team for the shopfloor: each service connects to the others when your project needs it.
Let’s look at your machines
Find out what your machines can tell you.
Tell us how many machines you run, their types and roughly how old they are. We’ll suggest how to connect them and what a pilot would cover.
The demo is free, at no cost and with no commitment.
- Emailbhupinderdagar@mfosys.in
- WhatsApp+91 99999 94453
