OEE Data Acquisition

The problem

OEE is calculated from manual logs, so availability, performance and quality figures are disputed and improvement projects start from guesswork.

Solution overview

MILESGO gateways collect data from production counters and machine state signals, PLCs, run/stop and fault dry contacts over S7 / Modbus TCP / EtherNet/IP / Modbus RTU, and deliver it to MES, a historian / database (MySQL, SQL Server, InfluxDB), large-screen dashboards (HDMI) as OPC UA / MQTT. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

production counters and machine state signals
PLCs
run/stop and fault dry contacts

Protocol path

S7 / Modbus TCP / EtherNet/IP / Modbus RTU → OPC UA / MQTT

Implementation checklist for the project manager

Agree KPI definitions (for example OEE components or kWh per unit) with operations before building dashboards.
Do not modify validated PLC programs; read existing data areas or add gateway-side mapping instead.
For hard-wired signals, list each DI/DO/AI/AO with its type (dry contact, 4–20 mA, 0–10 V, PT1000) and choose I/O modules accordingly.
Configure NTP so trends, alarms and meter readings carry consistent timestamps.
Confirm local storage so data survives network outages, and define the retention period.
List dashboard users and roles, and configure user permissions accordingly.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

System architecture

Field layer: production counters and machine state signals, PLCs, run/stop and fault dry contacts, connected over S7 / Modbus TCP / EtherNet/IP / Modbus RTU. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: MES, a historian / database (MySQL, SQL Server, InfluxDB), large-screen dashboards (HDMI), which receives the data as OPC UA / MQTT. Remote access for maintenance runs over VPN rather than open internet ports.

System composition

Field devices: production counters and machine state signals, PLCs, run/stop and fault dry contacts
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: MES, a historian / database (MySQL, SQL Server, InfluxDB), large-screen dashboards (HDMI) (OPC UA / MQTT)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Software and AI capabilities

Anomaly detection on trend dataRoadmap
Automatic report drafting from collected dataRoadmap

Delivery steps

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Customer value

Reliable trend data for optimisation and fault diagnosis
One view of all subsystems instead of separate vendor consoles
Monitoring added without changing existing control programs
Timestamped records for compliance and reporting

Tell us about your project

Send the protocols, point count and target system. A sales and engineering pair reviews every submission.

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