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Industries / Manufacturing

Sensors and monitoring that surface downtime early.

On the line, minutes of downtime are margin. We build the sensor networks, edge gateways, and monitoring that make OEE and failures visible before they reach the P&L — hardware and cloud from one team.

Contact usAll industries

A stopped line is money leaving the building — and it's measured in minutes, not months.

The manufacturing problem

The constraint

Downtime is margin.

The shop floor is a hostile place for electronics and networks, and a line that stops is margin walking out the door. We put rugged sensors and edge gateways on the machines, process at the edge so a network blip doesn't blind you, and surface OEE and failures before they become an outage.

  1. 01Rugged sensing built for the shop floor
  2. 02Edge processing that survives a network blip
  3. 03OEE and failures visible before the P&L feels them
  4. 04Firmware and cloud from one accountable team
Browser line-monitor console for a metalworks hall. KPIs show shift OEE of 84.2% in green, availability 91.4%, performance 95.5%, quality 96.5%, and 23 micro-stops. Four line rows carry filled OEE meters and states including running, vibration drift, and changeover. A machine table lists cycle times against target, vibration meters, temperatures, and micro-stops, with Press 12 flagged for drift. A right rail shows a cycle-time sparkline and an alert feed.

On the machines

The kit we put on the line.

When off-the-shelf sensing doesn't fit the machine or the environment, we design it.

01

Sensor nodes

Vibration, temperature, current, and cycle-count sensing, ruggedised for the floor.

02

Edge gateways

Local processing and buffering so a network blip never costs you a reading.

03

Machine & PLC taps

Integration with existing PLCs and controllers — no rip-and-replace.

04

Cloud telemetry

The dashboards, alerting, and OEE analytics behind the devices.

How we work

From machine to dashboard.

  1. 01

    Instrument

    We identify the signals that predict downtime and the ruggedised way to capture them.

  2. 02

    Build

    Sensors, edge gateways, and firmware — with the cloud telemetry designed alongside them.

  3. 03

    Pilot

    A line-side run to prove the signal is real and the hardware survives the floor.

  4. 04

    Scale

    Fleet rollout, OTA updates, and dashboards — operated with you or handed over.

In the field

Shift OEE at 84.2% against an 80% target, four lines with availability, performance, and quality broken out, and a vibration drift flagged before it stops the line.
48 edge gateways, a staged firmware rollout at 30 of 48 with rollback armed, and one site buffering 4,182 readings through a downed uplink — missed readings: zero.
The supervisor's pocket view: shift OEE with the meter filled, a vibration-drift alert with its 7-day trend, and acknowledge or raise-order one tap away.
A work order raised by the telemetry, not a breakdown: live sensor meters against alert thresholds, a signed checklist at 2 of 4, and the part it consumed.

Proof

How we instrument the line.

The bar every manufacturing build has to clear.

OEE
Surfaced in real time
Edge
Processing on-site
OTA
Firmware updates
24/7
Monitored

Signal to action

What we monitor, what you prevent.

What we monitor
  • Vibration and thermal signatures
  • Cycle time and micro-stops
  • Energy draw per machine
  • Availability, performance, quality (OEE)
What you prevent
  • Unplanned downtime and overruns
  • Failures that cascade down the line
  • Maintenance done too early or too late
  • Margin lost before anyone notices

Related work

Hardware and data, in the field.

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Building for one of these?

Tell us the constraints — uptime, compliance, field conditions. We'll come back with an architecture that fits.

Contact uscontact@protocore.io