Downtime Monitoring System
ANDON Station for Breakdown Monitoring
Our powerful ANDON Breakdown Monitoring System enables Plant Heads to gain real-time visibility into machine stoppages across the shop floor. By combining smart hardware signals with intelligent software dashboards, our solution instantly alerts the maintenance team, tracks response and resolution times, and provides actionable downtime analytics to reduce losses and improve OEE. Opus One ensures faster decision-making, greater accountability, and improved operational efficiency across your plant.
Instant Machine Breakdown Visibility
Faster Response
Reduced Downtime
Real-Time Visibility
Faster Response
Higher Productivity
16,000
Offline Storage capacity
60/minute
Capture Signals
Multi-colour
Tower Light
24×7
Live Production Monitoring
Pain Points in the industry
Why ANDON Breakdown Monitoring
Matters in Manufacturing?
The ANDON Station eliminates unnoticed breakdowns by combining visual factory alerts with digital MES monitoring,
ensuring every machine issue is immediately detected, escalated, and resolved.
Key Features
Key Features of the ANDON Station
ANDON station ensures clear communication with the shopfloor employees.
Multi-Colour ANDON Tower Light Signalling (Standard Industrial Stack Lights)
The system uses industry-standard ANDON tower light colors to indicate machine status clearly across the shopfloor.
- Green – Machine Running / Normal Production
- Yellow / Amber – Minor Issue or Attention Required
- Red – Machine Breakdown / Production Stoppage
- Blue – Material Shortage / Operator Assistance Required
- White (Optional) – Quality Check or Supervisor Call
High-intensity LED stack lights ensure visibility from long distances in large manufacturing shopfloors.
Manual and Automatic Breakdown Triggering
The ANDON station supports multiple methods for machine breakdown detection:
- Operator push-button activation
- PLC or machine signal integration
- Sensor-based stoppage detection
This ensures that both operator-reported issues and machine-detected faults are instantly captured in our MES system – Opus One.
Integrated with Opus One MES
Every ANDON alert is digitally recorded within the Opus One MES platform, enabling detailed production analytics.
- Breakdown start and end time
- Maintenance response time tracking
- Root cause selection
- Downtime categorization
- 4M analysis (Man, Machine, Material, Method)
This converts simple visual alerts into actionable manufacturing intelligence, helping improve maintenance efficiency and machine utilization.
Real-Time ANDON Dashboard Monitoring
Live machine breakdown status is visible across multiple manufacturing dashboards:
- Shopfloor digital display boards
- Production supervisor dashboards
- Maintenance monitoring screens
- Plant head performance dashboards
Colour-coded machine status tiles allow teams to instantly identify production issues across departments.
Universal Compatibility
Built for Every Machine,
Ready for Every Industry
Our Wi-Fi OEE Monitoring System seamlessly integrates with virtually any manufacturing equipment. From legacy machines to modern industrial robots, OpusOne adapts to your factory floor.
- CNC Machines
- VMC / VFC Machines
- Press Machines
- Injection Moulding Machines
- Industrial Robots
- Looms & Textile Equipment
- Assembly Lines
- Packaging Machines
Reliable Hardware, Industrial-Grade Performance
Purpose-built for demanding factory environments with enterprise-grade components and seamless connectivity options.
5 Custom Setups
Industrial Features
- Industrial-grade durability
- IP54 rated enclosure
- Anti-glare display
- Wide operating temperature
Barcode Scanner
Industrial Features
- IP54 rated enclosure
Display
Industrial Features
- Rugged usage for
Easy Installation
Plug. Play. Scale.
Real results that impact your bottom line within months, not years
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Unbox & Mount
Secure the OpusOne device near your machine using the included mounting bracket. No special tools required.
- Wall or panel mount options
- VESA compatible bracket
- Adjustable viewing angle
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Connect to Wi-Fi
Power on the device and connect to your factory Wi-Fi network through the intuitive setup wizard.
- Simple on-screen setup
- WPA2/WPA3 security
- Automatic reconnection
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Configure I/O
Connect sensor wires from your machine to the digital I/O terminals for automatic production counting.
- 3 digital inputs available
- 3 digital outputs available
- RS485 for PLC integration
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Start Monitoring
Access your real-time dashboard from any device. Your factory data is now visible 24/7.
- Web-based portal access
- Mobile responsive design
- Instant data visibility
System Requirements
Power Supply
12-24V DC, 2A min
Wi-Fi Network
2.4GHz or 5GHz
Signal Source
24VDC sensor output
Mounting Space
200 x 150 x 50 mm
Need Help with Installation?
Our technical team provides remote or on-site installation support to ensure your system is up and running smoothly.
Value & ROI
Measurable Gains.
Rapid Payback.
Real results that impact your bottom line within months, not years
5-20%
Productivity Gains
Optimized workflows and better resource utilization
Better
On-Time Delivery
Meet customer commitments consistently
Production
Smarter Production Outcomes
Consistent performance with fewer delays.
Lower
Scrap & Rework
Early defect detection reduces waste
10-30%
Reduced Downtime
Faster response to issues means less production loss
Quick ROI
3–9 Month ROI
Lower downtime. Faster returns.
Installation & Setup – Data Collection Analysis – Decision Making
Implementation of Decision
making & Improvement
observations
ROI Realization
Software & Data Flow
How Your Data Gets From OEE to Opus One Platform
Understand how OpusOne captures, transmits, and processes your production data todeliver actionable insights in real-time.
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Machine Signals
Digital I/O captures production events, cycle times, and machine states in real-time.
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Wi-Fi Transmission
Data is securely transmitted over your factory Wi-Fi network using encrypted protocols.
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Cloud Processing
Our servers process and analyze data, calculating OEE metrics and generating insights.
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Dashboard Access
View real-time dashboards and reports from any device, anywhere, anytime.
Sample Reports
Data-Driven Insights at Your Fingertips
Generate comprehensive reports automatically. From daily OEE summaries to detailed
downtime analysis, get the data you need to drive continuous improvement.
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Sample Report
Machine: RACB14
Request a demo
Ready to simplify your factory operations?
Manufacturing teams rely on real-time visibility to stay in control.
Trusted by growing teams worldwide
faq
Got questions? We’ve got
answers
Real results that impact your bottom line
within months, not years
What industries can benefit from OpusOne?
OpusOne caters to a wide range of industries including automotive, aerospace, consumer goods, and pharmaceuticals, enhancing their manufacturing processes with digital solutions.
How does OpusOne improve productivity?
By integrating automation and real-time data analytics, OpusOne helps identify bottlenecks, optimize processes, and increase overall operational efficiency.
What is the timeline for implementation?
The implementation timeline varies based on the complexity of your existing systems, but our team ensures a smooth and efficient transition.
Is OpusOne scalable for future growth?
Absolutely! OpusOne is designed to scale with your business needs, adapting to new technologies and processes as you grow.
Is OpusOne scalable for future growth?
Absolutely! OpusOne is designed to scale with your business needs, adapting to new technologies and processes as you grow.
Still have questions?
