Manufacturing Execution SystemShipped★ Featured
Real-time Production-Line MES
MES Theo dõi Dây chuyền Real-time
OEE dashboard for 6 assembly lines — PLC via OPC UA, per-minute downtime calc.
Node.jsOPC UATimescaleDBGrafanaPLC S7Docker
Problem
An electronics plant with 6 assembly lines. Supervisors didn't know which line was down or why until they walked over. High MTTR; each downtime hour ≈ $1,500. OEE was only calculated daily → interventions always too late.
Architecture
9 Siemens S7-1200 PLCs → OPC UA bridge (Node.js node-opcua) → state-machine engine classifies stops by bit-tag → TimescaleDB → 4K Grafana dashboard + custom Andon panel. Auto-alert when a line stops >2 min.
Stack & rationale
- OPC UA over Modbus: industry standard, secure (cert-based auth), self-documenting tag namespace.
- TimescaleDB: native timeseries on Postgres, 30-day OEE query <1 s.
- Node.js: node-opcua is the most mature open-source option.
Results (3 months)
| Metric | Before | After |
|---|---|---|
| MTTR (min) | 24 | 15 (−38%) |
| Avg OEE across 6 lines | 67% | 78% |
| Time-to-detect downtime | 8 min | 30 s |
| Daily production meeting | 45 min | 15 min (data on dashboard) |