Article Type: Concept / Application Overview
Audience: Solution Architects, Application Designers, Partners, Operations Managers
Module: Manufacturing / Production Management
Applies to Versions: 2025.1.1+

1. Overview

The Machine Monitoring application is a comprehensive, production-ready solution built on the Fuuz Industrial Operations Platform. It provides real-time visibility into manufacturing equipment status, calculates Overall Equipment Effectiveness (OEE) metrics, and enables operators to track production runs, manage machine modes, and respond to events—all through an intuitive, role-based interface.

This application serves as both a deployable manufacturing solution and a reference architecture demonstrating Fuuz platform capabilities including IoT integration, real-time data processing, automated calculations, and configurable dashboards.

2. Architecture & Data Flow

Key Definitions

• Workcenter: A production asset or machine being monitored. Workcenters have modes (running, idle, maintenance), can generate events, and produce countable outputs.
• OEE (Overall Equipment Effectiveness): A manufacturing KPI calculated as Availability × Performance × Quality. The application computes this metric hourly, by shift, and by production run.
• Mode: The current operational state of a workcenter (Production, Idle, Changeover, Maintenance, Disabled, or Other). Mode changes are tracked with timestamps for historical analysis.
• Event: A discrete occurrence affecting production (Running, Blocked, Starved, Idle, Planned Downtime, Unplanned Downtime, Disabled). Events can trigger alarms based on priority.
• IoT Tag: A reference to a PLC memory address or sensor value. Tags can be sourced from OPC-UA, MQTT, or internal Fuuz data and are mapped to workcenters for automated data capture.
• Production Setup: A configuration linking a workcenter to a product with associated rate targets and quality specifications.
• Shift: A defined work period with start/end times and day-of-week assignments. The application includes a default 3-shift configuration (6:00-14:30, 14:30-22:00, 22:00-6:00).

Application Components

Data Architecture

The application follows a hierarchical data model designed for manufacturing operations:

• Facility → Workcenter Groups → Workcenters: Organizational hierarchy for physical assets
• Workcenter → IoT Tags → Device Subscriptions: Equipment connectivity for real-time data collection
• Workcenter → Modes → Events: State tracking and downtime categorization
• Production Setup → Production Run → Production History: Work order execution and output tracking
• OEE → OEE Aggregate → OEE Dimensions: Multi-level performance metrics with configurable aggregation

3. Use Cases

Real-Time Production Monitoring

Operations managers and supervisors can monitor all workcenters from a centralized Plant Dashboard showing current modes, active alarms, and production status. The Workcenter Group Dashboard provides focused views for specific production lines or areas, with drill-down capability to individual Workcenter Dashboards.

OEE Tracking & Analysis

The application automatically calculates OEE every 10 minutes for all active workcenters, aggregating results by hour, shift, and production run. Analysts can use the OEE screen to configure calculation parameters, view historical trends, and identify improvement opportunities through the Hourly Production and Status by Shift visualizations.

Downtime Management

When equipment stops producing, operators use the Workcenter Mode Change screen to record the reason (Changeover, Maintenance, Idle, etc.). Events capture granular details (Blocked, Starved, Unplanned Downtime) for root cause analysis. The Mode and Events Gantt visualization displays shift timelines with color-coded state changes.

IoT Data Collection

Machine data is collected through IoT Tags configured for each workcenter. Tags support multiple protocols (OPC-UA, MQTT, Fuuz internal) and use cases (Production counts, Scrap counts, Mode signals, Event triggers). The IOT Tag Handler data flow processes incoming values and updates workcenter status automatically.

Alarm & Event Response

Events can be configured with priorities that automatically generate alarms. The Alarm State Change Screen Flow enables operators to acknowledge, escalate, or resolve issues. Event Categories provide additional classification for reporting and analysis.

Production Run Tracking

The Production Run Analysis and Production Run History screens enable tracking of work orders from start to completion, including setup time, actual production quantities, scrap reasons, and performance against rate targets. The Work Order Process Distribution screen supports dispatch planning and resource allocation.

4. Screen Details

Dashboard Screens

Analysis Screens

Administration Screens

5. Technical Details

Core Data Flows

Pre-Configured Visualizations

• OEE Doughnut / OEE Doughnut (Small): Displays Availability, Performance, and Quality components with overall OEE percentage
• Hourly Production: Bar chart showing production counts by hour with target comparison
• Mode and Events Single Workcenter Gantt: Timeline visualization of mode changes and events across a shift
• Workcenter Status by Shift: Stacked bar showing state distribution (Running, Idle, Down) by shift
• Workcenter Status By Shift Bar: Horizontal bar variant for compact dashboard layouts

IoT Tag Configuration

IoT Tags can be configured with the following parameters:

Shift Configuration

The application includes a pre-configured Default Shift Group with three shifts:

6. Implementation Approach

Phase 1: Installation & Configuration

1. Install the Machine Monitoring package in your Fuuz application environment
2. Configure Shift Groups and Shifts to match your facility's work schedule
3. Define Workcenter Groups reflecting your production line organization
4. Create Workcenter records for each machine to be monitored
5. Configure Mode Types and Event Types appropriate for your operations

Phase 2: IoT Integration

1. Deploy Fuuz Gateway to connect to PLC networks or data sources
2. Create IoT Tag records mapping PLC addresses to Fuuz data points
3. Associate IoT Tags with Workcenters using the Workcenter IoT Tag configuration
4. Configure Device Subscriptions for real-time data polling
5. Validate data flow by monitoring IoT Tag Historical Values

Phase 3: Production Setup

1. Create Production Setup records linking products to workcenters with rate targets
2. Configure OEE parameters (target rates, quality thresholds)
3. Set up Scrap Reason Codes for quality tracking
4. Assign roles to users (Administrator, Supervisor, Analyst, Maintenance)
5. Test end-to-end data flow from machine to dashboard

Phase 4: Go-Live

1. Train operators on Workcenter Control Panel for mode changes
2. Train supervisors on dashboard navigation and alarm response
3. Deploy dashboards to shop floor displays
4. Monitor OEE calculation accuracy and adjust configurations
5. Iterate on visualizations and reports based on user feedback

7. Extensibility

The Machine Monitoring application is designed as a foundation that can be extended using Fuuz platform capabilities:

Common Extensions

• ERP Integration: Connect to SAP, Oracle, or other ERP systems using Fuuz Data Flow connectors to sync work orders, materials, and production reports
• Quality Management: Add inspection points, SPC charts, and quality hold workflows
• Maintenance Management: Integrate with CMMS systems or build maintenance scheduling and work order tracking
• Advanced Analytics: Create custom visualizations using FusionCharts or export data to BI tools
• Mobile Interfaces: Design responsive screens for tablet-based shop floor data entry
• Notifications: Configure email or SMS alerts for critical events using Fuuz Notification Channels
• Document Generation: Create shift reports or production summaries using Fuuz Document Designer with Stimulsoft

Customization Points

• Data Models: Add custom fields to existing models or create new entities
• Screens: Modify layouts, add components, or create entirely new screens
• Data Flows: Extend business logic with additional processing steps or integrations
• Saved Transforms: Create reusable JSONata transformations for calculations and aggregations
• Roles: Add custom roles with specific menu access and permissions

8. Troubleshooting

9. Resources

• Fuuz Industrial Operations Platform — Main product site
• Screen Designer Documentation — Building custom screens and dashboards
• Data Flow Designer Documentation — Creating automated business logic
• Gateway Configuration Guide — Connecting to PLCs and data sources
• JSONata Reference — Expression language for data transformations

10. Revision History