Production data collection
Production data collection and archiving.
Every temperature, pressure, stoppage and part count stored with a timestamp in one place. We design and deploy production data collection and a historian that does not lose data even when a server fails.
The data is in your PLCs. It needs to be got out and kept.
Production data collection is the basis for everything you want to do with production next: finding the root causes of faults, cutting energy consumption, proving quality to the customer or calculating OEE. Control systems have this data, but they mainly hold current values. Without historisation the history is lost and all that remains is what someone wrote down by hand. Exactly when you need to find out what was happening three hours before a failure, the data is missing.
We design the architecture for collecting and archiving production data, from sensors and PLCs through communication modules and servers to visualisation and reports. For critical operations we deploy a high-availability historian: redundant collection interfaces that switch over automatically on a fault, and an archive spread across several servers. Data remains available even if the main server goes down, and the servers can be updated while running without any data loss.
We deployed an architecture like this on the FactoryTalk Historian platform, for example, at a chemical plant in cooperation with its IT department, which now manages it independently. We also collect data from remote sites, for example from heat meters via M-Bus and mobile networks with VPN, and fault messages from lines by different manufacturers into a single database. Alongside process variables we also historise service data, such as running hours or control panel door openings.
What production data collection delivers.
Historisation of process variables
Storing values from PLCs, sensors and meters with a timestamp and at a set resolution, going back years.
High-availability historian
Redundant collection interfaces and an archive on several servers. Neither a server fault nor maintenance leaves a gap in the data.
Visualisation and trends
Web-based trends and overviews for process engineers, energy managers and management, with data export for further analysis.
Reporting and archiving
Automatic shift and monthly reports, quality parameters linked to serial numbers and records for audits and customers.
Production data collection from remote sites
Remote monitoring of outstations via M-Bus, 3G and 4G networks and VPN, with encrypted transmission and local buffering if the connection drops.
Alarms and notifications
E-mail and SMS alerts when limits are exceeded, communication is lost or a machine fails, sent straight to the people responsible.
What the delivery includes.
We deliver the whole chain, from the signal in the PLC to the report on the production manager's desk.
- Analysis of data sources and design of the collection architecture
- Configuration of communication with PLCs, meters and other devices
- Communication modules for remote sites and older equipment
- Installation and configuration of the historian, including redundancy
- Visualisation, trends and web access
- Reports, exports and connection to MES or ERP
- Access security and separation of the production and office networks
- Administrator and user training
Platforms and protocols
How the cooperation works.
Consultation
We come to you, look at the operation or the brief and tell you what makes sense. Without obligation.
Concept and quote
Technical design, scope, schedule and price. Always with a reserve for what practice reveals.
Implementation
Engineering, manufacturing, installation, programming and commissioning. One team, one responsibility.
Operation
Operator training, documentation and a service contract according to how critical the technology is for your production.
Related services.
MES system
Production planning and scheduling, warehouse management, TPM maintenance, downtime and OEE in one system.
PLC programming
PLC control systems, HMI operator panels and SCADA for Siemens, Rockwell, ABB, Omron and Schneider.
Energy management
Optimising electricity and heat generation and consumption, renewables integration, battery storage and energy audits.
Frequently asked questions.
Did not find your answer? Write to us and we will reply within 24 hours.
How much does production data collection and archiving cost?
It depends on the number of sources and measuring points, the required availability, historian licences and the scope of visualisation and reports. In our project, a high-availability historian for a chemical plant came to tens of thousands of euros. We give a fixed price after analysing the data sources.
What is a historian and why do I need one?
A historian is a database designed for storing time series from production. It handles large volumes of timestamped values, compresses them efficiently and returns them quickly for trends and analysis. A standard SQL database is not built for that kind of load.
What does a high-availability historian mean?
The collection interfaces run redundantly and switch automatically to the standby on a fault, and the archive is spread across several servers. Production data therefore remains available even if the main server fails, and you can update the servers while running without losing data.
Which devices can you collect data from?
From Siemens, Rockwell Allen-Bradley and other PLCs, from SCADA systems, energy meters, weighing scales, sensors and older machines via added communication modules. We use standard protocols such as OPC UA, EtherNet/IP, PROFINET or M-Bus.
Will we be able to manage the system ourselves?
Yes, that is the aim. We design an open architecture and train your administrators so they can handle routine administration and add new points without us. We are on hand for larger changes and faults.
How long is the data kept?
According to your needs and legal requirements, typically for years. Thanks to compression, even a long history takes up a reasonable amount of space. Communication modules at remote sites keep a local buffer so nothing is lost if the connection drops.
Which data are you missing today?
Tell us which machines and systems you want to collect data from and what you need it for. We will get back to you within 24 hours with a proposed architecture and a free consultation.