PLC Data Collection

Structured, real-time production data straight from your PLCs.

The industrial problem

The PLC sees almost everything in a production line: machine states, counters, alarms, analog process values, cycle times, recipes. But that picture usually stays locked inside the controller or an isolated HMI – unavailable for OEE, downtime analysis, quality investigations, or AI.

How it works

We connect directly to your PLCs using their native protocols – Siemens S7, Beckhoff ADS, Omron, Mitsubishi, Allen-Bradley/Rockwell (EtherNet/IP) – as well as OPC UA and Modbus TCP where available. Tags are read at the rate the use case needs, buffered locally against network interruptions, and stored as clean, structured time series with consistent naming per machine and line.

Collection is non-intrusive: we read data without modifying your control logic, coordinate tag lists with your automation team, and respect the network separation between OT and IT. On top of the collected data we build dashboards, OEE and downtime analysis, alarm analytics, and the foundation for predictive maintenance and AI.

Typical data sources

  • Machine states, modes, and cycle times
  • Production counters and piece counts
  • Alarm and event registers
  • Analog values: temperature, pressure, current, flow
  • Recipes and setpoints
  • Energy meters connected to the PLC

Business value

  • A complete, objective picture of line behavior
  • OEE and downtime causes from real signals, not estimates
  • Alarm history that can finally be analyzed
  • The data foundation for condition monitoring and AI

Deployment architecture

  1. 1An edge collector connects to the PLCs over their native protocols
  2. 2Tags are read cyclically and buffered locally
  3. 3Structured time series land in on-premise databases
  4. 4Dashboards, reports, and AI applications consume the data

Integration

  • Siemens S7, Beckhoff ADS, Omron, Mitsubishi, Allen-Bradley
  • OPC UA and Modbus TCP
  • InfluxDB, SQL databases, Grafana
  • MES and ERP via APIs
  • Secure OT/IT network separation

Example use cases

  • Line OEE and utilization from PLC signals
  • Downtime cause analysis per machine and shift
  • Alarm frequency and pattern analytics
  • Energy consumption per cycle and per product
  • Cycle time trends feeding predictive maintenance

All solutions

Industrial Data Collection & Machine Connectivity
Predictive Maintenance & Condition Monitoring
Industrial AI Agents

Interested in this solution?

Tell us about your machines and processes – we will propose a practical architecture and a pilot you can evaluate.

Discuss your project