Industrial Monitoring & Reporting

Turn Field Data into Centralized, Actionable Information

NetRelay enables centralized monitoring of I/O data from production lines, machines, energy infrastructure and security systems. Information collected from digital inputs, sensors and device states improves real-time visibility across industrial operations.

Instead of generating continuous and unnecessary network traffic, the system can be designed to transmit meaningful state changes, critical events and periodically sampled data to central software. This helps use existing Ethernet and Wi-Fi infrastructure efficiently while reducing unnecessary communication load.

Event-Based Data Collection

Rather than continuously transmitting every I/O value, meaningful events such as machine start, stop, fault conditions, sensor threshold violations or security contact changes can be recorded and forwarded when required.

Publish/subscribe technologies such as MQTT allow only relevant information to be delivered to interested systems, helping manage network traffic efficiently in installations with many NetRelay devices.

Machine Runtime and Downtime Reports

Machine running and stop signals can be timestamped to calculate actual operating time, total downtime and number of downtime events.

Reports can be generated by shift, day, week or month, allowing teams to identify which machines experience the most downtime and when production losses occur.

Fault History and Repetitive Fault Analysis

Fault contacts from machines and control panels can be recorded centrally. Fault start time, recovery time and total fault duration can be analyzed historically.

This information helps identify machines with recurring problems and supports preventive and predictive maintenance planning.

Production and Shift Performance

Pulse signals from photoelectric sensors, proximity sensors or machine outputs can be used to count production. The data can be grouped by shift and compared against production targets.

Field Data for OEE

Runtime, downtime and production quantity collected through NetRelay can provide field-level data for OEE calculations in ERP, MES or custom production monitoring platforms.

MTBF and MTTR Analysis

Historical fault information can support maintenance KPIs such as Mean Time Between Failures and Mean Time To Repair, helping maintenance teams measure reliability and repair performance.

Energy Usage Reports

Data from suitable current, voltage or energy sensors can be used to monitor energy consumption trends across machines and production lines.

Energy data can be correlated with production quantities and machine runtime to calculate more meaningful indicators such as energy consumption per produced unit.

Alarm and Critical Event Reporting

Temperature alarms, power failures, generator activation, cabinet access, pump faults and network availability events can be stored with timestamps for historical analysis.

Example Reports

• Machine runtime reports
• Downtime duration and event reports
• Fault history reports
• Recurring fault analysis
• MTBF and MTTR maintenance reports
• Production quantity reports
• Shift performance reports
• Target versus actual production
• Machine and line energy reports
• Energy consumption per production unit
• Power failure and generator reports
• Temperature and environmental history
• Cabinet and technical area access logs
• Critical alarm history
• Device online/offline reports

Use Network Resources Efficiently

In installations with many field devices, continuously transmitting unchanged information can generate unnecessary traffic. Event-driven messaging, MQTT topic structures and configurable reporting intervals provide a more efficient communication architecture.

For example, a digital input does not need to continuously transmit the same state. A message can be generated only when the state changes. Sensor information can similarly be transmitted periodically or only when configured thresholds are exceeded.

Do More Than Monitor

Field information can also trigger automated actions. A critical temperature can activate ventilation, a machine fault can turn on a warning beacon and a network failure can initiate a controlled restart workflow.

Central Dashboard and Reporting

Data collected from NetRelay devices can be transferred to a central backend using MQTT, HTTP or TCP and stored in platforms such as PostgreSQL or time-series databases.

Production quantities, machine availability, active faults, downtime, energy consumption and critical alarms can then be presented through a centralized dashboard.

From Raw I/O to Actionable Information

A dry contact alone is simply a binary signal. Combined with the right software architecture, that same signal can become downtime information, fault frequency, maintenance performance or measurable production loss.

Use NetRelay to collect field data efficiently, minimize unnecessary network traffic, create historical reports and turn industrial I/O into actionable operational intelligence.