IMS machine monitoring and fault alert system
IMS monitors machine status from the PLC in real time, immediately notifies the responsible maintenance engineer when a fault occurs, and makes downtime measurable – on the plant’s own server, without the cloud.
What IMS does
- Real-time RUN / STOP / FAULT monitoring from the PLC
- Instant push and e-mail notification on faults
- Only the maintenance engineer assigned to the machine is notified
- Analytics: availability, MTTR, fault statistics
- Full audit log and acknowledgement workflow
- OPC UA based communication
- Runs on the customer’s own server, no cloud
- Quick rollout, ready to use in a short time
Goal: less downtime, faster fault handling, transparent maintenance.
Why machine monitoring?
On a production line, the cost of a stoppage does not start with the fault but with the fact that nobody knows about it. By the time the operator notices, calls maintenance and the right specialist arrives, valuable production time is lost. IMS shortens this time: at the moment of the fault, the maintenance engineer responsible for the machine receives a notification with the relevant data.
The collected data show which machines stand still most, which fault recurs, and how long it takes to fix faults. Maintenance becomes plannable, and improvement decisions are based on data.
How does it work?
- IMS connects to the machines’ PLCs via OPC UA and reads the status signals continuously.
- On a fault, it selects the person assigned to the machine based on rules and sends push and e-mail notifications.
- The maintenance engineer acknowledges the notification; every step goes into the audit log.
- The system calculates availability, mean time to repair (MTTR) and fault statistics.
Data stays on the plant’s own server – no cloud service, no risk of data leaking to external networks.
Rolling out IMS
- 01
Assessment
Collecting the machines and controls to monitor and the required status signals.
- 02
Connection
Setting up OPC UA connections with the PLCs, extending the PLC program if needed.
- 03
Rules
Setting up responsibilities, notification rules and permissions to match the plant’s organisation.
- 04
Training and operation
Training maintenance staff and managers, then ongoing support and extension.
Frequently asked questions
Does it need a cloud service or internet?
No. IMS runs on the plant’s own server; the connection needed to deliver notifications is set up according to the plant’s IT policies.
Which machines can it connect to?
Directly to OPC UA capable controls. For other controls, by extending the PLC program or via a gateway solution, based on an on-site assessment.
Can it be introduced on an existing production line?
Yes, without disrupting production, gradually machine by machine.
Related services
Let's talk about your task.
Briefly describe the process and the goal – we will get back to you shortly and suggest the next step.