Modern manufacturing environments generate large volumes of machine and production data. However, turning that information into actionable shop-floor intelligence becomes challenging when equipment, controllers, and data systems operate independently.
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Industry
Medical Device Manufacturing
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Solution
Industrial IoT, OEE Monitoring and Manufacturing Analytics
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Platform
Ignition SCADA with Perspective
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Deployment Model
Hybrid edge, on-premises and cloud architecture
For a global medical device manufacturer, PSPTech Hub delivered an Ignition-based manufacturing solution designed to bring machine status, production output, downtime, scrap, and Overall Equipment Effectiveness (OEE) metrics into a unified operational environment.
The solution connects shop-floor operations with enterprise analytics while giving manufacturing teams real-time visibility into production performance.
The manufacturing environment consisted of different production equipment, PLCs, CNC machines, industrial sensors, and data collection systems. Because equipment relied on different industrial communication methods, obtaining a consistent view of production performance across machines was complex.
Production teams needed near real-time answers to critical operational questions:
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Is a machine running, stopped, or experiencing downtime?
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What is the current production output?
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Is actual output meeting the shift target?
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How much downtime has occurred?
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Is the downtime planned or unplanned?
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What is the good production count versus scrap?
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How are Availability, Performance, and Quality affecting OEE?
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Which production losses require attention?
The challenge was not simply building another dashboard.
The manufacturer needed a standardized industrial data architecture capable of collecting machine information, applying production logic, and presenting meaningful OEE and production metrics from individual equipment through site-level views.
The solution also needed to accommodate plant-specific production configurations, including equipment hierarchy, production shifts, part numbers, ideal cycle times, downtime categories, and scrap reasons.
PSPTech Hub developed a centralized OEE and production monitoring platform using Ignition SCADA and Ignition Perspective.
The platform brings machine and production data into a responsive web-based application where manufacturing teams can monitor equipment and production performance from a common interface.
The application provides visibility into key manufacturing metrics:
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Availability | Performance | Quality | OEE | Good Count | Scrap | Runtime | Downtime | Production Target | Actual Output
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OEE = Availability × Performance × Quality
Instead of restricting users to high-level OEE percentages, the application provides visibility into the production conditions behind those metrics.
Manufacturing teams can move from site and production overviews into individual equipment views to investigate machine states, production output, downtime, scrap, cycle times, and actual production against defined targets.
The machine-level dashboard gives operators and manufacturing teams a visual representation of current production conditions.
The interface provides visibility into:
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MACHINE OEE DASHBOARD
Illustrative dashboard mockup — not customer data
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Availability
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Performance
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Quality
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OEE
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Production output | Shift target | Scrap | Runtime
Hourly production · target versus actual
Real-time Ignition Perspective dashboard displaying machine OEE, Availability, Performance, Quality, production output, shift targets, downtime, and equipment state.
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Availability, Performance, and Quality
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Overall Equipment Effectiveness
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Current machine status
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Production output
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Shift production target
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Actual versus target production
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Scrap quantity
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Runtime and downtime
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Part and cycle-time information
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Machine-state history
Visual machine states differentiate running, planned downtime, unplanned downtime, and downtime requiring classification, helping production teams understand equipment conditions without relying entirely on historical reports.
Hourly production views add further context, allowing manufacturing teams to compare actual output against targets and identify periods associated with downtime or production gaps.
The platform brings together several capabilities required to create a connected production environment.
At the operational level, the solution functions as an “Ignition OEE Solution”, combining machine data with production context to calculate and visualize critical manufacturing metrics.
The use of “Ignition SCADA” and Ignition Perspective provides the foundation for machine connectivity, application logic, and operational dashboards.
Rather than building separate monitoring interfaces for different production assets, the centralized “OEE Monitoring System” brings machine status, production counts, downtime, scrap, and OEE metrics together.
This enables “Real-Time Production Monitoring” across individual equipment and broader manufacturing views.
The resulting “Manufacturing OEE Dashboard” gives production teams access to Availability, Performance, Quality, OEE, runtime, downtime, and target-versus-actual information within the same operational environment.
Combined with PLC, CNC, sensor, and enterprise data integration, the architecture creates a foundation for “Industrial IoT Manufacturing” where shop-floor information can be transformed into production intelligence.
The solution was designed to provide visibility beyond individual machines.
Site-level and equipment-group views consolidate information from multiple assets, allowing users to compare production conditions and drill down into individual equipment when more detailed analysis is required.
The application provides operational views for:
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SITE OEE OVERVIEW
Illustrative dashboard mockup — not customer data
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Availability
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Performance
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Quality
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OEE
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Assembly Line
Running
CNC Machine
Planned downtime
Packaging Line
Running
Inspection Station
Planned downtime
Multi-machine manufacturing dashboard providing consolidated visibility into OEE, Availability, Performance, Quality, machine status, downtime, and production counts.
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Site overview
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OEE dashboard
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Production dashboard
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Machine overview
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Hourly production
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Andon monitoring
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Machine-state history
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Downtime analysis
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Production and scrap analysis
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Historical OEE analysis
Users can filter information across the manufacturing hierarchy and equipment, moving from site-level visibility to detailed machine performance.
One of the key requirements was supporting manufacturing equipment with different industrial connectivity options.
The solution combines Ignition native connectivity, OPC UA, MQTT, and Kepware KEPServerEX to bring production information from different types of industrial equipment into a common environment.
The technology landscape includes connectivity associated with:
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Allen-Bradley PLCs
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Siemens controllers
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Omron controllers
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CNC machines
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OPC UA devices
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Modbus TCP equipment
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MQTT-enabled devices
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Industrial sensors and data collection systems
Where direct connectivity is not suitable, Kepware KEPServerEX acts as an additional industrial connectivity layer between equipment and the Ignition environment.
This approach enables heterogeneous shop-floor assets to participate in a common production monitoring and OEE framework.
Accurate OEE monitoring requires more than collecting PLC tags. Machine data must be interpreted within the correct production context.
The platform therefore includes configurable manufacturing information covering:
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Plant and equipment hierarchy
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Production shifts
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Machine assignments
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Part numbers
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Ideal cycle times
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Planned downtime
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Unplanned downtime
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Downtime reason codes
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Scrap reason codes
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Non-scheduled production periods
Combining production context with machine data allows the application to present manufacturing KPIs under relevant operational conditions.
This provides manufacturing teams with visibility into not only the final OEE value, but also the Availability, Performance, Quality, machine-state, production, and downtime information contributing to that result.
The solution extends beyond the Ignition visualization layer by connecting operational production data with an enterprise data environment.
The manufacturing data architecture supports the following flow:
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Within this architecture:
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Ignition supports machine connectivity, manufacturing logic, OEE processing, and real-time visualization.
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Kepware KEPServerEX provides an additional industrial connectivity layer.
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PostgreSQL forms part of the operational data environment.
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Kafka and Kafka Connect support manufacturing data streaming.
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Qlik supports data movement and replication.
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Snowflake provides the cloud data layer for manufacturing information.
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Power BI supports enterprise-level manufacturing analytics.
This creates a connected path between shop-floor production monitoring and enterprise manufacturing analytics.
Ignition EAM also forms part of the environment supporting distributed Ignition deployments.
The solution established a centralized framework connecting equipment data, production context, OEE monitoring, and enterprise analytics.
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Centralized OEE Visibility
Availability, Performance, Quality, and OEE can be viewed alongside machine status and production information, providing a common operational view of manufacturing performance.
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Real-Time Production Monitoring
Ignition Perspective dashboards provide visibility into production output, manufacturing targets, machine states, runtime, downtime, and scrap.
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Multi-Machine Visibility
Manufacturing information from multiple assets can be consolidated into broader site and equipment views while allowing users to drill down into individual machines.
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Downtime Visibility
The platform distinguishes operational states including planned downtime, unplanned downtime, and downtime requiring classification, providing additional context around production interruptions.
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Target vs. Actual Production Tracking
Production dashboards bring defined targets and actual output together, while hourly production views provide additional visibility into performance over time.
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Connected Industrial Data
PLCs, CNC machines, sensors, and industrial data sources can contribute to the same manufacturing environment using technologies including Ignition, Kepware, OPC UA, MQTT, EtherNet/IP, and Modbus TCP.
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Shop Floor to Enterprise Analytics
Operational manufacturing information can move through PostgreSQL, Kafka, Qlik, and Snowflake into Power BI, connecting production operations with enterprise-level analytics.
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Industrial & SCADA
Ignition SCADA | Ignition Perspective | Ignition EAM | Ignition Tag Historian | Kepware KEPServerEX
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Industrial Connectivity
OPC UA | EtherNet/IP | Modbus TCP | MQTT / MQTTS | PLC Connectivity | CNC Connectivity
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Data & Integration
PostgreSQL | Microsoft SQL Server | Apache Kafka | Kafka Connect | Qlik | HiveMQ
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Cloud & Analytics
AWS | Snowflake | Microsoft Power BI
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Monitoring & Operations
Dynatrace | SolarWinds | Telegraf | ServiceNow
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Unified OEE monitoring:
Availability, Performance, Quality, OEE, production output, scrap, runtime, and downtime are brought into a centralized manufacturing environment.
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Real-time shop-floor visibility:
Ignition Perspective dashboards provide machine-level and multi-machine production views.
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Multi-vendor industrial connectivity:
Ignition, Kepware, OPC UA, MQTT, EtherNet/IP, and Modbus TCP support integration across different types of manufacturing equipment.
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Production context behind OEE:
Equipment hierarchy, production shifts, part numbers, ideal cycle times, downtime classifications, and scrap reasons provide operational context around manufacturing KPIs.
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Connected IT and OT data:
Production information can move from industrial equipment through Ignition and enterprise data technologies into Snowflake and Power BI.
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Scalable manufacturing data foundation:
The solution brings together machine connectivity, OEE calculations, downtime visibility, production intelligence, and enterprise data integration within a connected architecture.
The project demonstrates how an “Ignition OEE Solution” can connect heterogeneous shop-floor equipment with manufacturing intelligence, creating a foundation for real-time production visibility and enterprise-level analytics.
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Industrial IoT & OEE Expertise
Experience connecting industrial equipment, production data, and OEE monitoring into a unified manufacturing environment.
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End-to-End Manufacturing Integration
Integration expertise across Ignition SCADA, Kepware, industrial protocols, operational databases, and enterprise analytics platforms.
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Connected Manufacturing Intelligence
A structured approach to connecting machine status, production output, downtime, scrap, and manufacturing KPIs with enterprise analytics.
Discover how PSPTech Hub can help connect industrial equipment, improve OEE visibility, analyze production losses, and build a connected manufacturing data environment.
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