Solution · Manufacturing
OEE - Modbus + CCTV AI.
Line telemetry meets people context.
Plant managers and OEHS teams who see conflict between PLC data and what cameras show.
The challenge
The line says running. Cameras disagree.
Plant and safety teams argue from different truths - machine counters versus what patrol and CCTV show.
- 01
Machines look healthy; the cell is empty
Counters say fine while nobody is there or the line is blocked - downtime debates never end.
- 02
Rounds signed, proof missing
When something fails, time and place evidence is not there - only a signature.
- 03
Process and safety never share a timeline
Separate tools mean separate owners when an incident needs one story.
Sound familiar?
By the numbers
When PLC and CCTV disagree, the argument costs more than the sensor.
Plants lose hours reconciling machine state with people and patrol reality.
Split truth
line telemetry and video rarely share one incident timeline
*1
Paper rounds
still stand in for proof of time and place on many floors
*2
Shift loss
unexplained downtime debates eat supervisor time every week
*3
- *1 Common OT/IT gap in discrete and process plants - MES/PLC and CCTV owned by different teams.
- *2 OEHS / patrol compliance programs frequently rely on paper or disconnected apps.
- *3 Plant ops interviews during DGOS discovery engagements - downtime dispute time is a recurring cost.
How we solve it
Machines and people. One timeline.
Line data and camera checks in one operator view - presence and process on the same clock.
- 1
Line status plus who is there
See machine data next to camera checks for empty cells and process exceptions.
- 2
Patrol with proof
Time and place trails for rounds - not just a signature on paper.
- 3
One alarm list for the shift
Sensor and video events land in one dashboard the shift can act on.
This is the simpler path.
ROI conversation
One timeline for machines and people.
Productivity shows up as fewer arguments - and faster containment.
2–4×
faster exception triage
Sensor + video alarms land together for the shift lead.
Proof
on patrol compliance
Time and place trails replace signature sheets.
Clearer
downtime stories
Less finger-pointing between maintenance and production.
Multiples are planning targets from scoped OEE cells; protocol access and camera coverage set the ceiling.
How it works
From cell survey to shift view
- 01
Pick the cells
Which lines, cameras and protocols matter this quarter.
- 02
Wire collectors + AI
Industrial points and CCTV models for presence / exceptions.
- 03
Align alarms
One timeline for ops and OEHS.
- 04
Shift reports
Handover packs without spreadsheet archaeology.
Ready to map step one?
What's in the package
Visibility for the floor that ships.
Scoped for plants that need agreement between machines and people.
- Modbus / OPC UA / I/O collectors for the line
- CCTV AI checks for presence and process exceptions
- Patrol / round compliance timelines
- Combined sensor + video alarms
- Operator dashboard and shift reports
After go-live
What teams notice first
One truth for line status and people on it
Patrol compliance with time and place proof
Fewer unexplained downtime arguments
Want outcomes like these on your site?
End the line-vs-camera argument.
Walk us through one cell. We will show the combined picture before you commit.
Built on
FAQ
Production line visibility - FAQ.
OT and quality leads comparing PLC dashboards with camera-backed exceptions.
Do you replace MES / SCADA?
No. We bridge sensor and video context so exceptions have proof - MES stays the system of record for orders and recipes.
Plant network rules?
Edge-first design keeps inference and recording close to the line. Northbound links follow your OT/IT zoning.
Which lines first?
Usually the line with the most expensive false stops or quality disputes - one cell proves the pattern before a plant roll-out.
Is computer vision mandatory?
No. Start with PLC / meter sync if that is the pain; add vision modules where a picture settles the argument.
Shift handover?
Shared timelines and alarm context are part of the package so night and day shifts stop reconstructing history from chat apps.
Tell us the problem — we'll shape the solution.
A short discussion. No pitch theater. We listen, then compose a clear path.