Real-time monitoring of production parameters

Purpose

1.1 Enable real-time capture, visualization, and automatic response to deviations in critical production parameters (temperature, pH, flow rate, tank levels, alcohol content, etc.) to comply with strict regulatory standards and QA requirements.
1.2 Allow automated data logging, compliance reporting, operator notifications, and audit trails, ensuring traceable, consistent production and minimizing manual intervention/errors.

Trigger Conditions

2.1 Parameter readings entering a predefined risk zone (e.g., temperature > set threshold) from PLC, SCADA, or IoT sensors.
2.2 Scheduled or periodic data polling fails or a sensor disconnects or returns an anomalous value.
2.3 Regulatory event, such as start/end of batch requiring automatic logging.
2.4 QA process step triggers, such as sampling events or operator checks.

Platform Variants

3.1 Amazon IoT Core
• Feature/Setting: MQTT topic subscriptions for device data streams; configure alarms via AWS IoT Events.
3.2 Microsoft Azure IoT Hub
• Feature/Setting: Event Grid integration for device telemetry; set up alert rules in Azure Monitor.
3.3 Siemens MindSphere
• Feature/Setting: MindConnect connectivity; set up Data Flows for real-time condition monitoring.
3.4 Google Cloud IoT Core
• Feature/Setting: Device registry; set Pub/Sub topic triggers for incoming sensor data.
3.5 Schneider Electric EcoStruxure
• Feature/Setting: EcoStruxure Machine Advisor; configure real-time dashboards and event notifications.
3.6 Ignition by Inductive Automation
• Feature/Setting: Tag Group alarms and notification pipelines for PLC tags.
3.7 OSIsoft PI System
• Feature/Setting: PI Data Archive for historian data; Event Frames and PI Notifications for real-time alarms.
3.8 Honeywell Experion
• Feature/Setting: Experion SCADA Event and Alarm management; OPC connectivity configuration.
3.9 Yokogawa FAST/TOOLS
• Feature/Setting: Alarm Management module and OPC DA/UA data interfaces.
3.10 Rockwell Automation FactoryTalk
• Feature/Setting: Alarm & Event Servers; configure alarm triggers on Tag properties.
3.11 Emerson Plantweb
• Feature/Setting: Plantweb Insight app data sources and automated email/SMS/SCADA notifications.
3.12 Aveva System Platform
• Feature/Setting: Alarm response objects; configure event triggers for historian records.
3.13 ThingWorx
• Feature/Setting: Data Streams for sensor input and Alerts/Subscriptions for events.
3.14 SAP Plant Connectivity
• Feature/Setting: OPC DA/HDA connectors for real-time read and alert push to SAP MII.
3.15 InfluxDB/Telegraf
• Feature/Setting: Telegraf agent input plugins for Modbus/OPC/HTTP; configure Kapacitor alert rules.
3.16 Ignition Perspective Module
• Feature/Setting: Web/Mobile dashboards and push notifications for alarm subscriptions.
3.17 Node-RED
• Feature/Setting: Input nodes for MQTT/OPC-UA/SNMP; set up Switch/Function nodes for alarm routing.
3.18 Splunk Industrial Data & IoT Module
• Feature/Setting: TCP/UDP input for sensor streams; Real-time alert triggers and notification actions.
3.19 Wonderware Historian
• Feature/Setting: Real-time Historian tags; set alarms on changing tag values, notification configuration.
3.20 Datadog
• Feature/Setting: Custom metrics ingestion from IoT gateways; monitor and trigger outputs via Datadog Monitors.

Benefits

4.1 Continuous, auditable parameter monitoring; minimized risk of non-compliance.
4.2 Automatic alerts and intervention guidance; reduced manual workload.
4.3 Enhanced traceability for regulatory and internal audits.
4.4 Early detection of system failures or process deviations, reducing quality incidents.
4.5 Accelerated and automatic reporting, freeing skilled staff for higher-value activities.