Turn Existing Machines Into Your Industrial IoT Solution.
HARDWARIO supplies retrofit-ready field devices and documented interfaces. Your integration team owns the production application, data, customer value, and rollout.
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
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.
Review your projectHidden 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 supplies their input to the partner-owned application, which timestamps, routes, and acknowledges the event.
How We Help
OEE Monitoring
Collect supported machine-state signals and feed them through documented interfaces into the OEE calculation your application owns; quality and performance inputs remain part of the customer workflow.
Predictive Maintenance
Supply current, vibration, and temperature signals to the maintenance logic your team designs and validates for changing machine behavior.
Machine State Tracking
Collect running, idle, stopped, or fault signals and let your production application model and visualize the states relevant to each line.
ANDON Systems
CHESTER Push supplies a rugged, timestamped worker trigger; your application defines notification routing, acknowledgment, and escalation.
OEE Monitoring
Collect supported machine-state signals and feed them through documented interfaces into the OEE calculation your application owns; quality and performance inputs remain part of the customer workflow.
Predictive Maintenance
Supply current, vibration, and temperature signals to the maintenance logic your team designs and validates for changing machine behavior.
Machine State Tracking
Collect running, idle, stopped, or fault signals and let your production application model and visualize the states relevant to each line.
ANDON Systems
CHESTER Push supplies a rugged, timestamped worker trigger; your application defines notification routing, acknowledgment, and escalation.
Your production application on a retrofit-ready foundation.
You define the machine model, business logic, user experience, and data destination. HARDWARIO supplies field devices and documented integration interfaces.
Capture machine state
Count pulses on four isolated PNP inputs. External PLC, SCADA, or software clients read GAUGER's totals through Modbus TCP or REST.
Detect load and anomalies
Measure current draw to confirm utilization and spot abnormal behavior before it becomes a maintenance event.
Escalate from the line
Give operators a rugged one-button ANDON trigger; the partner-owned application records the event and manages notification, acknowledgment, and escalation.
Deliver data to your application
Read GAUGER directly through Modbus TCP or REST, and use supported CHESTER Cloud REST API, webhooks, or exports where that path fits.
"Deploying CHESTER Push has enabled us to respond quickly to the needs of individual sites, eliminate unnecessary downtime, and streamline the entire logistics process."
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.
isolated PNP inputs
GAUGER counts machine pulses and exposes its own totals to external clients.
GAUGER interfaces
Integrate the counter without claiming that GAUGER reads PLCs or meters.
typical scoped pilot target
Applies to a catalog-based live-data pilot; custom paths are scoped separately.
Results buyers can verify
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.
Products for Manufacturing
GAUGER
GAUGER is our industrial IoT counter - it counts pulses from PLCs and industrial sensors for OEE and downtime reporting, and retrofits on a DIN rail without disrupting production.
CHESTER
CHESTER is our modular industrial IoT platform with cellular IoT, LoRaWAN, and BLE connectivity - battery-powered for years and field-proven down to -40°C in Canadian winters.
CLOUD
HARDWARIO Cloud handles secure message passing between your devices and systems - with REST API integration, firmware updates over the air (FOTA), and remote device shell.
Prove one production workflow, then make it repeatable.
A typical scoped catalog pilot can target live data in 2-4 weeks. Custom machine interfaces, firmware, or certification paths are scoped separately.
Define the production question
Choose the line, machine states, alert rules, and KPI that will make the pilot commercially obvious.
Install and validate signals
Attach sensors or connect to PLC signals, verify data quality, and configure dashboards and alerts in the partner-owned application.
Run with operators
Use real production shifts to validate downtime reasons, response time, and maintenance triggers.
Decide the rollout
Review the baseline, quantify savings, and package the bill of materials for the next machines or sites.
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.
Or call directly: +420 775 159 734