Manufacturing

Stop Downtime. Improve OEE.

Real-time machine monitoring and predictive maintenance that keeps your production running at peak efficiency - deployed in days, not months.

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40%

less downtime

unplanned stops eliminated

20%

OEE improvement

real-time visibility

6 mo

payback period

typical for line monitoring

100%

legacy compatible

works with any PLC or machine

The Reality

Common challenges

Unplanned downtime costing thousands per hour

No visibility into actual OEE metrics

Legacy equipment without connectivity

Manual data collection is unreliable

Reactive maintenance instead of predictive

Worker safety blind spots on the factory floor

Cost of delay

Downtime is only the visible loss

Most plants already know when a line has stopped. The sales opportunity is catching the smaller losses that happen before a stoppage becomes obvious.

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Hidden idle time

Short stops, missing material, and slow changeovers rarely make it into manual reports, but they quietly reduce available capacity every shift.

Late maintenance signals

Current draw, vibration, and temperature usually change before a failure. Without live monitoring, the warning stays inside the machine.

Untrusted OEE

When availability and performance are typed in by hand, production teams debate the numbers instead of fixing the bottleneck.

Escalation delays

Operators know about problems first. CHESTER Push turns that knowledge into a timestamped alert maintenance can act on immediately.

Key Applications

How We Help

OEE Monitoring

Automatically calculate Overall Equipment Effectiveness with accurate availability, performance, and quality data from every machine.

Predictive Maintenance

Monitor current draw, vibration, and temperature to predict failures before they cause downtime. Alert maintenance teams while there's still time to act.

Machine State Tracking

Real-time visibility into machine states - running, idle, stopped - across the entire factory floor. Identify bottlenecks and hidden capacity.

ANDON Systems

CHESTER Push enables instant worker-initiated alerts when production issues occur, reducing response time from minutes to seconds.

OEE Monitoring

Automatically calculate Overall Equipment Effectiveness with accurate availability, performance, and quality data from every machine.

Predictive Maintenance

Monitor current draw, vibration, and temperature to predict failures before they cause downtime. Alert maintenance teams while there's still time to act.

Machine State Tracking

Real-time visibility into machine states - running, idle, stopped - across the entire factory floor. Identify bottlenecks and hidden capacity.

ANDON Systems

CHESTER Push enables instant worker-initiated alerts when production issues occur, reducing response time from minutes to seconds.

Recommended architecture

A practical path from one line to plant-wide visibility

Start with the signals that prove machine availability, then add predictive maintenance inputs and connect the data to dashboards, alerts, and existing MES or BI tools.

GAUGER

Capture machine state

Read PLC data over Modbus or RS-485, or count pulses on older equipment to separate running, idle, stopped, and fault states.

CHESTER Current

Detect load and anomalies

Measure current draw to confirm utilization and spot abnormal behavior before it becomes a maintenance event.

CHESTER Push

Escalate from the line

Give operators a rugged one-button ANDON trigger with automatic event logging for faster response and cleaner root-cause analysis.

HARDWARIO Cloud

Deliver usable data

Send alerts, feed dashboards, and integrate through REST API, MQTT, and webhooks without replacing existing production systems.

"Deploying CHESTER Push has enabled us to respond quickly to the needs of individual sites, eliminate unnecessary downtime, and streamline the entire logistics process."

Bohumil Čapek · Project Manager

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Proof

Built for pilots that become standards

The right first deployment should answer a production question quickly, prove the economics, and become repeatable across machines, lines, and sites.

30-50%

less unplanned downtime

Typical reduction target when machine state, alerts, and predictive inputs are deployed together.

10-20%

OEE improvement

A realistic gain when teams can see true availability and act on bottlenecks during the shift.

6 mo

typical payback

Focused pilots are designed around a measurable line problem rather than a broad platform rollout.

Customer proof

Results buyers can verify

Manufacturing pilot

Machine data without a production-line rebuild

Before: The team needed OEE and downtime visibility from existing equipment without replacing PLCs or stopping the line for a long integration.
Deployment: CHESTER Current and worker-initiated alerts captured machine state, idle time, and escalation events from a focused production cell.
Result: The buyer could compare planned production with actual machine behavior and package the same bill of materials for the next machines.

Metric

Days to first signal

Product used

CHESTER Current

Review OEE configuration

Products for Manufacturing

GAUGER

GAUGER reads utility meters optically - no wiring, no meter replacement, instant deployment.

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CHESTER

CHESTER is our ruggedized IoT gateway that operates in extreme conditions from -40 to +85°C.

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CLOUD

HARDWARIO Cloud provides secure data infrastructure with REST API, MQTT, and ready-made integrations.

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Pilot plan

A first production line can be live in days

Keep the first deployment narrow enough to prove value, then repeat the same architecture across similar machines.

Day 1

Define the production question

Choose the line, machine states, alert rules, and KPI that will make the pilot commercially obvious.

Days 2-5

Install and validate signals

Attach sensors or connect to PLC signals, verify data quality, and configure dashboards and alerts.

Week 2

Run with operators

Use real production shifts to validate downtime reasons, response time, and maintenance triggers.

Weeks 3-4

Decide the rollout

Review the baseline, quantify savings, and package the bill of materials for the next machines or sites.

FAQ

Buyer questions

Do we need to replace existing PLCs or MES systems?

No. HARDWARIO is designed to retrofit existing equipment and send usable data into the tools you already use.

Can this work on legacy machines with no data interface?

Yes. Machine state can be inferred from current draw, pulse counting, external contacts, vibration, temperature, and operator input.

What should the first pilot measure?

Start with one commercial problem: unplanned downtime, hidden idle time, slow response to line issues, or a critical machine with rising maintenance risk.

Build Your Next Solution for Manufacturing

Tell us about your customers and use case. We will help you pick the right configuration and get your first deployment running.

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Or call directly: +420 775 159 734