Machine Monitoring Application

Version: 1.0.5 Platform: Fuuz ≥ 2025.1.1 Enterprise: MFGx Spec Version: 2.0.0

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Overview

The Machine Monitoring Accelerator is a comprehensive, production-ready Fuuz application for real-time shop floor visibility, OEE (Overall Equipment Effectiveness) tracking, and IoT-driven machine data collection. It provides the full operational layer between physical manufacturing equipment and digital production records — capturing machine states, production counts, scrap events, downtime, and alarms in real time.

Built around the ISA-95 manufacturing hierarchy and ISO 22400 OEE standards, this accelerator supports discrete and process manufacturers who need accurate, shift-level machine performance data without custom development. It integrates with PLCs and OPC-UA devices via IoT tags, generates hourly OEE records, aggregates performance across configurable dimensions (product, work order, shift, workcenter group), and surfaces all data through operator-facing dashboards and management-level plant views.

Core Capabilities

• Real-time machine state tracking — Workcenter mode changes (production, idle, maintenance, changeover, unplanned downtime) recorded as an immutable history log with timestamps, duration, and shift assignment
• Automated OEE calculation — Hourly Availability × Performance × Quality computation per workcenter per shift; aggregated across configurable time frames (daily, weekly, monthly) and dimensions (product, work order, etc.)
• PLC-integrated production counting — Counter accumulator logic tracks raw PLC pulse counts, derives production quantities via delta comparison, supports multi-cavity/multi-output workcenters, and posts production records automatically or on-demand
• IoT device subscriptions — Subscribes to OPC-UA device tags, maintains current and historical tag values, routes incoming IoT messages to the correct production or mode-change handler
• Event and alarm management — Structured event taxonomy with priority levels, escalation logic (level-1 / level-2 notification timers), alarm lifecycle (new → acknowledged → cleared/canceled), and Gantt-ready downtime history
• Shift scheduling engine — Day-of-week shift schedules with configurable start/end times, timezone support, and creditAtStart flag for cross-midnight shift date attribution
• Operator control panel — Per-workcenter HMI screens for mode selection, production setup, output management, scrap recording, and badge-in/out
• Plant dashboard — WorkcenterGroup-based multi-machine views showing live OEE, current mode/event, production rates, and alarm counts

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Package Contents

machine-monitoring/
├── manifest.json
├── definition.json
├── package-data.json
├── data/                        34 seed data files
├── dataFlows/                   38 automation flows
├── dataModels/                  78 data model definitions
├── savedTransforms/             22 reusable data transforms
└── screens/                     84 UI screen definitions

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Functional Areas

1. Workcenter Management

Workcenters are the atomic unit of machine monitoring. Each physical machine or work cell is represented as a Workcenter record with configuration for:

• Production modes — Linked to a ModeGroup which contains an ordered ModeList of valid Mode records. Each mode entry can have a plcCode for PLC-driven automatic mode switching and an optional associated EventGroup for structured event capture.
• Shift scheduling — Assigned to a ShiftGroup for OEE shift resolution. The engine looks up the active shift at any given moment using the workcenter's shift group assignment.
• OEE rate configuration — Default ideal rate stored at workcenter level; overridden at the ApprovedWorkcenter (product-operation) level for product-specific takt time calculations.
• External system sync flags — productionHistorySync, runSync, and workcenterHistorySync flags control whether production data flows from an external ERP rather than being originated in Fuuz.
• IoT tag binding — Many-to-many WorkcenterIotTag junction associates OPC-UA tags from connected devices to a specific workcenter for counter reading, mode signals, and scrap signals.
• Facility assignment — Workcenters are optionally grouped under a Facility (type: Production, Distribution, or Subcontract) following the ISA-95 site hierarchy.
• WorkcenterGroups — Cross-cutting logical collections (independent of ERP setup) used to build plant-level dashboards. Groups have externalId for ERP mapping and customData for extended metadata.
• Current state pointer — currentWorkcenterHistoryId (unique foreign key) always points to the open WorkcenterHistory record, enabling instant current-state lookups without a query scan.

2. Production State & Setup

The ProductionSetup table functions as a one-per-workcenter "live state" record — the single source of truth for what the machine is currently doing:

• Current mode — modeId reflects the active Mode; changing this creates a new WorkcenterHistory record and triggers OEE recalculation for the hour
• Current event — eventId references a specific Event from the workcenter's configured ModeGroup event lists; event updates modify the open WorkcenterHistory record without creating a new one
• Current production run — productionRunId links to the active ProductionRun when the workcenter is executing a scheduled job
• Operators on duty — operators (JSON array) tracks who is logged in; used in labor efficiency calculations
• Static bulletins — note field stores free-text instructions visible on operator dashboards without triggering system events
• Outputs — One-to-many ProductionSetupOutput records, one per active product/work-order/cavity combination

ProductionSetupOutput is where PLC integration and production tracking converge:

• outputId — cavity number for multi-cavity dies (enabled by Workcenter.multiOutCapable)
• counterInput / counterAccum / counterLastProduction — three-field PLC counter accumulator: counterInput = last raw PLC value; counterAccum = total accumulated across PLC resets; counterLastProduction = counter value at last production post; production quantity = counterInput − counterLastProduction
• autoProduction — when true, the IoT pipeline automatically posts production records on each counter update instead of waiting for operator confirmation
• unitPerCycle — floating-point multiplier for dies that produce multiple parts per machine stroke
• standardQuantity / idealRate / setupRate — rate targets sourced from linked ApprovedWorkcenter for the product-operation combination
• producedQuantity / scrappedQuantity — running totals for the current setup
• remainingBalance / dueAt / scheduledStartAt — work order schedule data for operator guidance
• distributionStatus / workOrderProcessDistributionId — WMS integration hooks for distribution workflow coupling

3. Production History

ProductionHistory is the immutable append-only ledger of all production and scrap transactions. Every quantity posted — whether from operator entry, PLC auto-production, or ERP sync — creates a record here.

Key fields: - quantity — units produced or scrapped (required) - occurAt — timestamp of the event (defaults to $moment() at creation) - creditedAt — adjusted date for shift attribution (controlled by Shift.creditAtStart for cross-midnight shifts) - transactionTypeId — links to TransactionType defining the nature of the record (productionAdd, scrapAdd, productionSetupAdd, productionSetupClear, modeChange, etc.) - shiftId — resolved shift at time of posting; used for OEE aggregation - workcenterId / approvedWorkcenterId / productionRunId / scrapReasonId — full traceability chain - externalId — NetSuite Work Order Completion or Assembly Build ID for ERP reconciliation

Traceability fields (for regulated manufacturing): - serialNo — auto-sequenced from serialNumbers sequence - lotNo, heatNo, heatCode, masterUnitNo, trackingNo — material genealogy - productNumber, productNumberRevision, productRevision — revision-controlled product identity - operationCode, operationNumber, workOrderNumber — routing and shop order linkage

dataChangeCapture is enabled and exposed, enabling downstream event streaming for ERP integration.

4. OEE Calculation & Reporting

OEE is calculated per ISO 22400: OEE = Availability × Performance × Quality

Hourly OEE (Oee model): - One record per workcenter per shift-hour per shift - shiftHour — 1-based hour index within the shift (e.g., hour 3 of an 8-hour shift) - availability — productionTime / totalTime; productionTime = scheduled time minus unplanned downtime - performance — (totalQuantity × averageCycleTime) / productionTime; uses idealRate from ApprovedWorkcenter or Workcenter default - quality — totalProductionQuantity / (totalProductionQuantity + totalScrapQuantity) - counter — total machine cycles from PLC or manual entry for the hour; used when cycle time is more reliable than rate - plannedDowntime / unplannedDowntime / other — seconds in each state category for the hour - creditedAt — adjusted report date (respects Shift.creditAtStart for cross-midnight shifts) - Indexed on (workcenterId, workcenterGroupId, shiftId, shiftHour, startAt, endAt) and (workcenterId, shiftId, creditedAt) for fast dashboard queries

Aggregated OEE (OeeAggregate model): - Rolled-up OEE across configured dimensions with weighted averages (availabilityWeight, performanceWeight, qualityWeight) - Linked to OeeConfiguration (which dimensions to apply) and OeeTimeFrame (duration in seconds — daily/weekly/monthly) - Dimension slicing by productNoRevision, workOrderCode, workOrderNumber, shiftId, workcenterId, workcenterGroupId - OeeConfiguration.lastRanAt is automatically set to the start of the configured time frame in America/Detroit timezone when a configuration is created

OEE Time Frames (OeeTimeFrame): - label — auto-set as the record ID via create trigger - duration — seconds (e.g., 86400 = daily, 604800 = weekly, 2592000 = monthly) - Used by scheduler to determine when aggregate recalculation runs

Key data flows: - Calculate OEE — core system flow; triggered on WorkcenterHistory changes, computes hourly Oee record - Get OEEs for shift — integration flow serving dashboard OEE query by shift date range - Get OEEs for shift Production Run — integration flow filtering OEE by active production run

5. Workcenter History & Downtime

WorkcenterHistory is the time-series log of every machine state change:

• Each record represents one continuous interval at a single mode/event combination
• occurAt — start of the interval ("logDate")
• endAt — end of the interval ("time resolved"); null for the currently-open record
• duration — endAt − occurAt in seconds; used directly in OEE time component calculations
• disabled — set from Event; marks the interval as "machine down" for OEE runtime calculation
• includeInOee — set from Mode; determines if interval counts toward OEE scheduled time
• requireNote — forces operator to enter a note before the record can be closed
• modeId / eventId — snapshot of mode and event active during this interval
• productionRunId — links to the run active at time of state change
• shiftId — resolved shift for time attribution

Back Fill End Dates data flow handles edge cases where records are left open across shifts or system restarts, ensuring OEE calculation always has complete time windows.

6. Event & Downtime Taxonomy

A three-level event taxonomy provides structured downtime classification:

EventType — defines OEE impact flags: - running, starved, blocked, idle, disabled (unplanned downtime for OEE), plannedDowntime, unplannedDowntime

EventCategory — 8-way classification: - equipment, labor, material, quality, schedule, ancillary, support, other

EventPriority — defines escalation thresholds: - redMinutes / yellowMinutes — age thresholds for visual alerting - critical, high, low, medium — priority tier flags - configurationSchema — JSON schema for priority-specific metadata capture

EventGroup / EventList — groups events for assignment to Mode entries: - EventList associates an Event to an EventGroup with display order, default flag, plcCode for IoT-driven selection, requireNote, and optional EventPriority - alarm flag on EventList triggers automatic alarm creation when that event is selected (see Create Alarm on Event flow)

Event — individual downtime/event entries: - externalId — PLC integer code for automatic event assignment from IoT signals - eventCategoryId, eventTypeId — taxonomy linkage - customData — extensible metadata

7. Alarm Management

Alarms provide escalating notification when workcenters enter abnormal states:

• Alarm records are auto-created by the Create Alarm on Event flow when an EventList entry has alarm: true
• alarmStatusId → AlarmStatus tracks lifecycle state with Boolean flags: new, active, acknowledged, cleared, canceled
• workcenterHistoryId (unique) — one alarm per open workcenter history record; cleared automatically when the interval closes
• levelOneSent / levelTwoSent (DateTime) — escalation timestamps; populated when notifications fire at configured priority thresholds
• assignedRoleId / assignedUserId — enables alarm routing to specific personnel or roles
• acknowledgedAt, assignedAt, canceledAt, clearedAt — full lifecycle audit trail
• TTL on updatedAt: ~32 million seconds (~1 year) — old closed alarms auto-expire

Alarm State Change Screen Flow — handles operator interactions from the alarm management screen, driving status transitions.

8. Mode Management

Mode — named machine states with OEE impact flags: - idle — machine is not producing but is healthy - includeProductionCounts — whether production posted in this mode counts toward OEE quality numerator - usable — controls availability in operator mode selection lists

ModeType — classifies modes into 6 operational categories: - production, idle, changeover, maintenance (planned downtime), disabled (unplanned downtime), other - Each ModeType has a color for visual differentiation in Gantt and dashboard views

ModeGroup / ModeList — per-workcenter configuration of which modes are available: - ModeList entries carry display order, default flag, plcCode for PLC-driven switching, and optional EventGroup for event prompting when that mode is selected - WorkcenterModeChangeLaunch screen flow — initiates mode change from operator HMI - Change Workcenter Mode integration flow — applies the mode change, creates WorkcenterHistory record, triggers OEE recalculation - No Mode Group Configured screen flow — error handler for workcenters missing mode group assignment

9. IoT Integration

Full OPC-UA device integration pipeline:

Device → Tag → Workcenter pipeline: 1. Devices (OPC-UA servers, PLCs) are registered in the platform 2. IotTag records define individual tag subscriptions: name, configuration (JSON — endpoint, node ID, polling interval), iotTagTypeId, iotTagUseCaseId, storeHistory flag, currentValue (JSON — last received value), currentValueRecordedAt 3. WorkcenterIotTag junction maps each tag to one or more workcenters 4. Create Device Subscription From Iot Tags — system flow that generates OPC-UA subscriptions on the device from the IotTag configuration 5. Update Iot Tag by Device Subscriptions — receives subscription update events, updates IotTag.currentValue 6. Create Historical IOT Tag Values — when storeHistory = true, appends each update to IotTagHistoricalValue for trend analysis 7. IOT Tag Handler — the main routing flow; reads iotTagUseCaseId to determine if incoming value triggers production posting, mode change, scrap recording, or counter update

IotTagUseCase controls dispatch routing: - Use cases map to specific handler behaviors (e.g., "Production Counter", "Mode Signal", "Scrap Signal", "Generic") - configurationSchema per use case defines the expected tag configuration structure

7-day data change capture on IotTag (exposed) enables real-time streaming of tag value updates to connected systems.

10. Shift & Scheduling

Shift — defines a single named work period: - startHour/startMinute, endHour/endMinute — local time bounds - timeZone — IANA timezone string for shift resolution - Day-of-week flags (monday…sunday) — all default true; set false to exclude days - creditAtStart — when true, production from a cross-midnight shift (e.g., 11 PM–7 AM) credits to the start date rather than the end date; critical for accurate daily production reporting for third-shift operations

ShiftGroup — named collection of shifts assigned to workcenters: - Multiple workcenters share the same shift group for consistent OEE shift resolution - usable flag controls active assignment

11. Product Rate Configuration

ApprovedWorkcenter — product-operation-workcenter rate configuration: - code — auto-sequenced identifier - idealRate — takt time target (the denominator in OEE performance calculation when product-specific rates are configured) - crewSize, setupCrewSize, setupTime — labor standard data - standardProductionRate, standardQuantity, targetRate, unitsPerCycle (Int) — production standard references - operationCode, operationNo, productOperationId — routing linkage - productId, productNo, productNoRevision, productRevision — product identity at the revision level - active — enables/disables without deleting historical records

ScrapReason — configurable scrap classification: - code — unique identifier (also the display label) - plcCode — IoT signal value that auto-posts a scrap record for this reason - externalId — ERP scrap reason code for two-way sync - usable — controls availability in operator scrap entry screens

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Data Flows

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Data Models

Core Machine & Workcenter

Production

OEE

Events & Alarms

Modes

Shifts

IoT

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Screens (84 total)

Screens provide operator-facing HMI panels, management dashboards, and configuration interfaces:

Operator HMI - Workcenter control panel with mode selection, event logging, production entry, and scrap recording - Multi-output production setup for multi-cavity workcenters - Badge-in / badge-out operator tracking - Alarm acknowledgment and escalation views

Plant / Line Dashboards - WorkcenterGroup overview — live OEE, current mode/event, production vs. target - Mode/Event Gantt chart — time-axis view of machine state history per shift - OEE trend views — hourly, shift, daily, weekly, monthly breakdowns

Configuration Screens - Workcenter setup — mode group, shift group, IoT tag assignment, rate configuration - Shift and ShiftGroup management - Mode, ModeGroup, ModeList configuration - Event, EventGroup, EventPriority configuration - AlarmStatus configuration - OeeConfiguration and OeeTimeFrame management - ScrapReason and TransactionType management

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Seed Data (34 records)

Pre-configured reference data included on install:

• ModeTypes — production, idle, changeover, maintenance, disabled, other (with default colors)
• TransactionTypes — full set of 31 named transaction classifications with color assignments
• AlarmStatuses — new, active, acknowledged, cleared, canceled with Boolean flag presets
• EventTypes — running, blocked, starved, idle, planned downtime, unplanned downtime
• EventCategories — all 8 categories (equipment, labor, material, quality, schedule, ancillary, support, other)
• EventPriorities — default priority levels with escalation minute thresholds
• IotTagTypes and IotTagUseCases — standard OPC-UA tag type and use-case classifications
• OeeTimeFrames — daily (86400s), weekly (604800s), monthly (2592000s)

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Key Integrations

ERP / External Systems

• ProductionHistory.externalId — NetSuite Work Order Completion / Assembly Build ID
• ScrapReason.externalId — ERP scrap reason mapping
• WorkcenterGroup.externalId — ERP workcenter group mapping
• Workcenter.externalId — external system machine ID
• Sync flags: productionHistorySync, runSync, workcenterHistorySync — enable pull-from-ERP mode per workcenter

PLC / OPC-UA

• WorkcenterMode.plcCode — integer code sent by PLC to trigger mode changes
• ModeList.plcCode — PLC code for mode signal routing
• EventList.plcCode — PLC code for event signal routing
• ScrapReason.plcCode — PLC code for scrap signal routing
• IotTag.configuration — full OPC-UA subscription configuration (endpoint, node ID, interval)
• ProductionSetupOutput.counterInput/Accum/counterLastProduction — three-register PLC pulse counter accumulator

Printing / Labeling

• Workcenter.printerId → Device — label printer assigned to each workcenter for production record labeling

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Installation

1. Ensure Fuuz platform version ≥ 2025.1.1 is deployed in the target environment
2. Import the package via Fuuz Package Manager using manifest.json (specVersion 2.0.0)
3. Seed data (34 records) will be applied automatically on first import — ModeTypes, TransactionTypes, AlarmStatuses, EventTypes, EventCategories, EventPriorities, IoT reference data, and OEE time frames
4. Configure ShiftGroup and Shift records for your facility's schedule (start/end times, timezone, day-of-week flags, creditAtStart for third shift)
5. Create ModeGroup and ModeList entries defining valid modes per workcenter type, with PLC codes if PLC integration is in scope
6. Create EventGroup and EventList entries for structured downtime classification; assign priority levels and enable alarm flag on critical events
7. Create Facility and WorkcenterGroup records following your ISA-95 site hierarchy and plant dashboard layout
8. Create Workcenter records and assign ShiftGroup, ModeGroup, Facility, WorkcenterGroup, and optional screenId
9. Configure ApprovedWorkcenter records for each product-operation-workcenter combination requiring product-specific OEE rate standards
10. For IoT/PLC integration: create IotTag records with device and OPC-UA node configuration; run Create Device Subscription From Iot Tags flow; map tags to workcenters via WorkcenterIotTag; configure iotTagUseCaseId to route signals to the correct handler
11. Configure OeeConfiguration and link to OeeTimeFrame and OeeDimension records for automated OEE aggregation reporting
12. Activate operator screens and plant dashboards from the Screens library; assign screenId to Workcenter records for per-machine control panel routing

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Dependencies

• Fuuz Platform ≥ 2025.1.1 — required for specVersion 2.0.0 package support
• Device / OPC-UA module — required for IoT tag subscription pipeline (flows 5, 6, 7, 14)
• Scheduler module — required for automated OEE aggregate recalculation and back-fill flows
• Notification module (optional) — required for alarm escalation level-1/level-2 email/SMS delivery
• ERP Connector (optional) — required when productionHistorySync, runSync, or workcenterHistorySync flags are enabled on any Workcenter

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Built on the Fuuz Industrial Operations Platform — Documentation