solutions / machine operations & service response
Plant · IIoT · BASF
The line calls. Someone always answers.
An andon and machine-operations platform for BASF's assembly line - service calls raised straight from the PLC, answered, measured and analysed.
Where this started
On an assembly line, the expensive minutes are the ones between something going wrong and the right person knowing about it. BASF's stations needed a way to call for help without anyone leaving the machine - and the plant needed those calls measured, so response times and failures stopped being anecdotes.
Decision 01
The line calls; software answers.
Stations raise a service call straight from the PLC - the backend polls Modbus TCP holding registers and opens a cycle the moment a station signals. No app at the machine, no walking to find a supervisor. Each call carries its full equipment chain: station, assembly, equipment, sub-equipment.
Decision 02
Every response is on the record.
A call moves Called → Open → Closed, with a named respondent and a timestamped history for every transition - cancellations tracked separately for stations and respondents. Manual tickets and breakdown flags cover what the push-buttons don't.
Decision 03
Breakdowns earn an analysis, not just a fix.
Calls flagged as breakdowns flow into a Root Cause Analysis queue - assigned, reviewed, approved, exported to PDF. Closing the call is not the end of the story; MTBF and MTTR per equipment come straight from the cycle history.
The result
BASF's line now has a paper trail for every minute that used to vanish - who was called, who came, how long it took, and why it broke. Machine running status hangs on the dashboard, MTBF and MTTR are computed from real response history, and breakdowns end in an approved root-cause analysis instead of a shrug.
Calls without leaving the machine
Station push-buttons read over Modbus TCP open service cycles automatically - polled from PLC holding registers.
Response accountability
Named respondent and timestamped history on every transition - Called, Open, Closed, or cancelled by either side.
Failures measured, not remembered
MTBF and MTTR per equipment from cycle history, with RCA approval required on every breakdown.
Under the hoodNode.js · Modbus TCP · React · MUI · ECharts · PostgreSQL
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