Machine monitoring software that reaches every machine, even the old ones
Connected via plug and play, SYMESTIC's machine monitoring software captures states, cycles, part counts and stops of every machine automatically: modern ones via OPC UA, older ones via digital signals, without touching the controller.
< 3 h
first machine live
15,000+
Machines connected
without
PLC intervention
15 countries
with customers
Your machines produce data. It just does not arrive anywhere.
Machine data collection only helps if it reaches every machine, runs automatically and needs no PLC project.
No interface
Older machines have no modern controller, their data stays in the machine.
Slips of paper or nothing at all
Part counts and stops are noted by hand, late and with gaps.
Every machine its own software
The new machine comes with the manufacturer's dashboard, the next one with a different one. For an overview, you click through several programs, and the numbers do not add up.
Eccentric press
Built 1994
Lathe
Built 1999
Injection molding
Built 2007
Automatic punching machine
Built 2003
Welding robot
Built 2012
Laser cutter
Built 2016
CNC milling machine
Built 2019
Assembly line
Built 2023
How SYMESTIC captures your machine data
Connect, plug and play.
SYMESTIC's Cloud Gateway, free software on your server, reads the data of modern machines directly from the controller via OPC UA. You connect older machines through their digital signals, using SYMESTIC's IoT Box, a one-time hardware purchase. Your electricians mount it themselves, without changing the PLC.
Cloud Gateway
Free software on your server
IoT Box
Hardware for digital signals or OPC UA, no server needed
Make comparable.
Signals from all manufacturers end up in one standardized data model. That makes machines, lines and plants comparable.
Data model
Signals become KPIs.
State (running, stopped, changeover), cycle and part count are shown live and calculated directly into OEE, utilization and downtime analyses, linked to order and shift.
What is included
Connection via plug and play
Via OPC UA or digital signals, after which capture runs automatically.
Machine states live
Running, stopped, changeover, plus cycles, part counts, downtime duration.
Reduce stopsMore machines in minutes
Once the Cloud Gateway or IoT Box is set up, new machines are added by configuration in the cloud.
What our customers achieve
Machine monitoring and production tracking: who captures what
Calculate what downtime costs
The downtime cost calculator shows what one hour of downtime costs on your machine.
Works well with
Frequently asked questions
What is machine monitoring (machine data collection)?
The automatic capture of machine data such as states, cycles, part counts and stops directly from the machine. It is the basis for OEE, downtime analysis and production control.
What is the difference between machine monitoring and production tracking?
Machine monitoring captures machine data (states, signals), production tracking captures operating and order data (times, quantities, status). SYMESTIC combines both in one system.
What are examples of machine data?
State (running, stopped, changeover), cycle time, part count, downtime duration and reason, controller alarms and process values such as temperature, pressure or energy consumption.
Which machine monitoring software delivers reliable machine data for production optimization?
Reliable means: captured automatically instead of retyped, from all machines instead of only the modern ones, with a timestamp and a link to order and shift, and defined the same way across plants. Check with every vendor how older machines are connected, whether data is buffered during a network outage and whether KPIs are calculated the same way in each plant. SYMESTIC meets this with OPC UA and the IoT Box (connection via digital signals), local buffering and a standardized data model.
Does machine monitoring also work with older machines?
Yes. The IoT Box taps the digital signals, even on machines without a modern controller, without changing the PLC.
Do I need new hardware for machine data collection?
Not necessarily. You capture machines with OPC UA through SYMESTIC's Cloud Gateway, free software on one of your servers or computers. The IoT Box only comes in if a machine does not speak OPC UA or you do not want to provide a computer: hardware you buy once that reads the machine's signals, without changing the PLC. On request, it transmits over cellular, bypassing your plant network.
How quickly can a machine be connected?
First machine in under 3 hours, first use case running in days.
How is machine data analyzed?
Automatically turned into OEE, utilization, downtime analyses and process values, live on dashboards and in reports, linked to order and shift.
Can machine data be compared across multiple plants?
Yes. All plants use the same standardized data model, so the KPIs are comparable 1:1. Multi-plant analytics
Machine monitoring software or MES: what do I need?
Machine monitoring is the start. Once confirmations, orders or quality come in, a platform pays off. SYMESTIC delivers machine monitoring as part of the cloud MES.
How secure is the data?
Microsoft Azure with data stored in the EU, German regions on request, encryption in transit and at rest. ISO 9001, GDPR, ISO 27001 under review.
See your machine data live.
In the live demo, we show how a machine like yours is connected, even an old one. 30 minutes, free of charge.
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
Book a demo with Christian
30 minutes · Microsoft Teams · no obligation
No preparation needed. All that helps is: which machines do you run, and which ERP do you use?
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