The UDMTEK platform monitors production lines to detect stoppages, unexplained machine interruptions, alarms, and abnormal operational patterns. By interpreting PLC control logic, the system pinpoints the exact root cause of equipment issues and supports predictive maintenance. The platform analyzes the execution sequence and logical relationships within the PLC program, examining the behavior of contacts, coils, and interlocks.
The system integrates Gantt timelines, PLC ladder logic, signals, and video into a synchronized analysis. By aligning time sequences and control logic, it identifies the true root cause of alarms and stoppages down to the PLC contact and step level, enabling precise and logic-based troubleshooting.
The system analyzes cycle time and control unit time trends to detect gradual performance degradation. By monitoring long-term changes, it identifies abnormal patterns early and helps determine the root cause of efficiency loss, enabling proactive maintenance and stable production performance.
We analyze historical alarm data to identify patterns, frequency, and duration by type. By linking alarms with PLC control logic, it traces the true root cause of recurring issues. Visual dashboards such as pie charts and histograms help quickly detect abnormal alarm trends and repetitive problems.
UDMTEK detected a timing mismatch between a vehicle detection sensor and MES data delivery to the PLC. This micro-timing gap caused repeated silent stops during model changeovers. By modifying the control logic signal type, the issue was resolved, preventing downtime and saving about $20M annually.