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Alarm management software: see machine alarms in one place and prioritize them, then trace them to the root cause

SYMESTIC's alarm management software collects the alarms and messages of all machines in one place, links them to downtime and alerts you when a condition you defined is met.

Alarm management software: alarm timeline and active alarms next to production data in SYMESTIC

Every controller reports. Nobody sees the pattern.

Modern machines generate thousands of alarms a day. They appear on the machine's display, are acknowledged and are gone. Which alarm precedes a stop, which machine throws the same message again and again, nobody sees that way.

Alarms, three machines, early shift

Example

2,418 alarmsLinked to downtime
Machine
06:0008:0010:0012:0014:00

Press 4

Hydraulics, tooling

Welding cell 2

Robot, guard door

Paint line

Dryer, conveyor

AlarmA-231 Hydraulic pressure lowDowntime

Pattern: A-231 precedes all 3 stops on Press 4

Rule: 2× A-231 in 60 min → push to maintenance

How alarm management works in SYMESTIC

Capture centrally.

SYMESTIC's Cloud Gateway reads alarms and messages directly from the controller via OPC UA. It runs on site and also captures alarms that are active for only a few milliseconds.

Cloud Gateway · Press 4 14:32:07.214 · A-231 Hydraulic pressure low 14:32:07.219 · A-118 Guard door open 14:32:07.483 · E-017 Cycle time exceeded 14:32:08.002 · A-231 Hydraulic pressure low

Prioritize and link.

You decide which alarms matter. The live view shows alarms next to the stops, so that connections become visible.

Priority · set by you
HighA-231 Hydraulic pressure low
MediumA-118 Guard door open
InfoA-004 Lubrication interval reached

React in time.

When freely defined conditions are met, for example a certain alarm several times within an hour, a message goes out by push or email to the people responsible.

IFA-231 at least 2× in 60 min
THENPush and email to maintenance

What is included

Central alarm monitoring of all machines

Prioritization of alarms for your analysis

Notification based on freely definable conditions, by push or email

Linked to downtime and orders

Analysis of the most frequent alarms per machine and period

Also captures alarms that are active for only a few milliseconds

Who it is for

What our customers achieve

Meleghy Automotive

From pilot to group solution, implemented by your own team.

−10%Downtime
+7%Output
4 plants
productive in 6 months
Carcoustics

Replacement of an existing MES, fully connected in 6 months.

8Countries
3Continents
510
segments across 12 plants
Yanfeng

First machines in operation after just one day and KPIs analyzed worldwide.

>95%less CAPEX
20+Sites connected
>90%
shorter project time for machine connection
Klocke Gruppe

GMP-regulated pharmaceutical packaging: from the pilot line to all lines at the site, without touching the PLC.

0PLC interventions
3 weeks
until all lines are live
Schmiedetechnik Plettenberg

After a joint workshop, the key users run SYMESTIC on their own; Customer Success only supports on occasion.

Day 1Real-time data at the line
100%Real-time transparency
100%
Self-sufficiency

Works well with

Frequently asked questions

What is alarm management in production?

The systematic capture, prioritization and analysis of the alarms and messages from machines, so important alarms do not get lost and recurring causes are identified.

Which alarms can SYMESTIC capture?

Alarms and messages issued by the controller. The Cloud Gateway reads them via OPC UA, including those that are active for only a few milliseconds.

How will I be notified?

By push to the smartphone or by email as soon as a condition you defined is met.

See your alarms in context.

30 minutes, free of charge.

Christian Fieg

Christian Fieg

Head of Sales · SYMESTIC

Over 25 years in the manufacturing industry · Six Sigma Black Belt · global MES rollouts in automotive

“I will also tell you in the conversation if SYMESTIC does not fit your production. That saves us both time.”

What you take away from the call

A first assessment of what will measurably improve in your plant: OEE, downtime, reporting effort
The answer to how your machines and your ERP would actually be connected (via OPC UA, digital signals or the REST API)
A realistic pilot scope: one line, one use case, a clear time frame

Book a demo with Christian

30 minutes · Microsoft Teams · no obligation

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No preparation needed. All that helps is: which machines do you run, and which ERP do you use?

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Customers in 15 countries ISO 9001 “SYMESTIC gives us end-to-end real-time transparency that we did not have in this form before.” Thorsten Manns, Technical Director, Schmiedetechnik Plettenberg