One unplanned downtime loss far exceeds monitoring investment
A sudden key equipment outage on the production line costs an entire shift's output and delivery deadlines.
Product Solution 08 / 08
Factory Equipment Monitoring & Alerting System
Online monitoring of production line electromechanical equipment, early warning before abnormal downtime to reduce unplanned outage losses
Solution Overview
Online monitoring of factory electromechanical equipment, collecting temperature, vibration, and operational status, identifying abnormal downtime with early warnings to reduce unplanned outage losses.
Discrete manufacturing workshopsInjection molding and metalworking linesPackaging and conveyor linesUtility equipmentSmall pump stations and dust removal equipment
Problems Solved
Equipment status judged by experienced technicians listening to sounds
Experience is hard to replicate and institutionalize. When personnel turnover occurs, on-site diagnostic capability drops directly.
Alerts disconnected from maintenance
Knowing there's an anomaly but no one dispatched, or lacking processing records — the same problem recurs repeatedly.
Traditional Solution vs ZHIYUAN
TraditionalZHIYUAN
Alert MethodFixed threshold alerts: only fire at limit crossings, blind to slow degradation. A single fault floods dozens of useless alerts, burying real risks.AI time-series anomaly detection: learns each device's baseline, catches slow drift and hidden anomalies. 80% fewer false alarms, alerts routed to the right people.
Notification & ClosurePhone calls/group chat: alerts dumped in chat, who handles what? Night alerts buried, discovered next day.WeCom/SMS graded push + work order automation: graded, person-specific routing. Unacknowledged alerts auto-escalate. Full traceability: alert → work order → resolution → archive.
Integration & RetrofittingCostly retrofit & downtime: new monitoring needs rewiring, equipment swap, production stoppage — long cycle, lost output.Reuse existing sensors, plug & go live: compatible with 95% DTUs/sensors. MQTT/Modbus standard protocols. No production line changes — 30-minute data integration.
Data ValueReal-time only, no history: manual logs capture instant values only — no trend visibility, can't replay fault evolution.Time-series database + history replay: massive long-term storage, any-range curve playback with work order records to reconstruct full fault picture and continuously improve O&M strategy.
Key Features
Key equipment online monitoring
Collect temperature, vibration, current, and run/stop status per equipment registry into a unified view.
Pre-failure sign identification
Compare against historical normal operating characteristics; identify abnormal temperature rise, increasing vibration, and abnormal start-stop frequency.
Downtime event recording
Automatically record downtime timing, duration, and associated alerts; output downtime statistics.
Alerts push directly to responsible person
Push to WeCom or SMS per workshop/team; automatically escalate if unacknowledged beyond timeout.
Alert-to-work-order conversion
One-click generation of repair work orders; processing steps and replaced parts documented into equipment health records.
Data Collection & Alerting Specs
Collected Data
- Equipment run/stop status
- Bearing and housing temperature
- Vibration values
- Current and power (optional)
- Start-stop count and runtime
Alert Types
- Unplanned downtime
- Persistent elevated temperature
- Vibration exceeding limit or rising trend
- Device offline
- Alert unacknowledged timeout
Alerts pushed to Web dashboard and WeCom; SMS as optional add-on. Same-type alerts auto-merged for noise reduction.
Deployment & Billing
- Deployment
- Collect existing sensor signals via on-site DTU; surface-mount vibration-temperature sensors can also be added. No production stoppage during installation — single-point modification typically completed within the shift.
- Billing
- Priced by combination of device count and point count; supports pilot on 1–3 key devices first.