Monitoring Tool & Predictive Maintenance

A new standard that enables you to prevent, not just react

Monitoring Tool is a toolkit built on Grafana, Prometheus, and OpenTelemetry that enables comprehensive oversight of production environments. The solution integrates data from multiple sources—machines, sensors, and IT systems—and presents it in clear dashboards. In practice, this means that instead of reacting after a breakdown, you can schedule maintenance based on real production signals—aligned with the principles of Industry 4.0.

Why does this solution matter?

Instead of reacting after a failure, you can prevent it

Up until now, maintenance was reactive: a machine would fail, production would halt, and the team would analyze the causes and look for a fix.

Monitoring Tool reverses this pattern. By monitoring and analyzing real-time data, you can detect early warning signs and plan service actions before they affect production. This elevates technical data—such as vibration, voltage, and temperature—from mere archival logs to predictive and planning tools that support stable, efficient production. This is the essence of Predictive Maintenance: data analysis helps identify patterns—performance drops, vibrations, overheating, or elevated voltage—and advises which components require attention before they cause downtime. That way, you perform servicing exactly when needed—avoiding costly surprises.

With Monitoring Tool, you can:

set customized warning and alert thresholds,

monitor which parts wear out faster and under what conditions,

plan maintenance and component replacements at the optimal time,

reduce the risk of unplanned downtime and shorten response time.

What challenges are manufacturing companies facing today?

Lack of real-time data access

70% of companies don’t use real-time machine data, leading to delayed decision-making.

Time-consuming reporting

Manually preparing reports extends the analysis process by up to 40%, burdening technical teams.

Scattered information

Machine, sensor, and IT system data are siloed, making it difficult to identify root causes and correlations.

Unplanned downtime

Unplanned downtime can cost up to 10 times more than scheduled maintenance. Without predictive capabilities, companies waste time and resources on unpredictable repairs.

How does Monitoring Tool solve these problems?

Complete production overview

Data from machines, sensors, and systems is centralized—giving you a clear, consolidated view of operations.

Data-driven decisions

Real-time and historical readings enable teams to make informed technical decisions—no guesswork required.

Act before the problem escalates

The system triggers alerts at the first sign of deviation, allowing maintenance to be scheduled proactively.

Flexible architecture

Start with a single dashboard and scale the system across lines, plants, or locations.

Seamless integration

Monitoring Tool uses OPC Gateway—no PLC interference or costly infrastructure changes needed.

IT stability and security

The solution runs on-premises or in the cloud, aligning with your company’s security policies.

What does the implementation process look like?

We select machines and key parameters, build the first dashboard, and demonstrate the system with real production data.

We set up views and alerts, and train your team to work independently with the tool.

We expand the solution to additional machines and lines, integrating it with ERP, CMMS, or quality systems.

We support you in building predictive models and evolving the system to match your company’s needs.

What do you gain by working with us?

Real-time access to data – no more delays from manual reports.
A solution tailored to your factory’s actual conditions.
Automated analysis and reporting – faster response times.
Reduced maintenance costs through planned servicing.
A stable, scalable architecture ready for further automation.
Technical and strategic support – at every stage of the project.

Where is Monitoring Tool & Predictive Maintenance used?

Manufacturing sites with assembly lines and CNC machines

Automotive, aerospace, and heavy industries

Energy and FMCG sectors

Companies investing in predictive maintenance and digital transformation

Series production where consistency and quality are critical

Monitoring Tool & Predictive Maintenance helps shift from intuition to data-driven decision-making. With real-time monitoring and trend analysis, companies gain process predictability, reduce downtime, and lower maintenance costs – fully aligned with the Industry 4.0 vision.

FAQ

Grafana Monitoring provides a centralized, visual interface for real-time monitoring of metrics across machines, infrastructure, and applications. Instead of dealing with fragmented data sources, you get a unified view that enables immediate detection of system load, performance issues, or potential failures. This ensures full transparency throughout your entire production process.

Grafana stands out for its flexibility, high scalability, and intuitive interface – including interactive dashboards and custom visualizations. It’s free (open source), easily extendable via plugins, and supports Unified Alerting as a centralized alert management system. As a result, it often outperforms commercial tools in terms of efficiency and adaptability.

We begin with a workshop to identify your requirements and use cases. Then, following our 4D model, we implement Grafana by connecting it to your data sources – such as Prometheus, InfluxDB, or log files – and build dashboards and alert rules. Our goal is seamless integration into your existing IT/OT environment.

During the workshop, you’ll learn the basics of Grafana: connecting data sources, creating dashboards, setting up alerts, and modeling use cases. If needed, we’ll also run a short demo or connect your pilot data. The goal is hands-on learning with immediate value.

You’ll need a data source – such as Prometheus, InfluxDB, or logs from your production environment. A stable network connection and a server (local or cloud-based) are also required. In some cases, a metric collection agent (e.g., Prometheus Node Exporter) or log aggregator may be needed.

Yes – we work with you to define key metrics (e.g., system load, response times, error rates) and design dashboards that provide the most value. Upon request, we set threshold alerts, configure notifications, and help interpret results in a business or production context.

Grafana supports role-based access control, secure authentication, and optional encryption. We make sure sensitive data stays local or under your control. From the planning stage, we involve your IT department to align with compliance requirements, data protection regulations, and internal policies.

We offer hands-on training for both IT and production teams – from the basics to building dashboards independently. We also support the change process: communication, documentation, operating instructions, and feedback rounds help your staff understand, accept, and effectively use the solution.

Grafana is especially useful where full visibility of production processes, fast error detection, resource optimization, and process monitoring are critical. Clients use it for predictive maintenance, production control, and energy/resource usage analysis. In implementation projects, dashboards often complement internal control centers or MES systems – they are quickly and efficiently integrated.

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