General & discrete manufacturing
Automotive and parts, machinery, metal fabrication, plastics and food & beverage: compressed air, process cooling, finishing, OEE and energy per part.
How FacilityOS helps
- Compressed-air plant with specific power, cooling water, paint-shop exhaust, lighting and energy by workshop.
- Boiler stack CEMS to EPA Part 60 / Part 75.
- PID loops, controller redundancy and Siemens S7 / EtherNet/IP PLCs alongside the facility systems.
- CMMS with preventive maintenance by run hours and starts counted from the equipment itself.
Platform modules used
Facility management and control
The whole cooling and power chain at a glance, with redundancy, shift handover, utility efficiency and first-out alarm analysis.
Learn more →EMSEnergy management system
Electricity, gas, water and steam metering by workshop and system, time-of-use cost, demand, carbon, PUE and tamper-evident report archives.
Learn more →PLC / DCSProcess control
PID loop faceplates, ISA-88 batch records, controller redundancy, EtherNet/IP and Siemens S7, and a soft-PLC IDE with simulation.
Learn more →CEMSContinuous emissions monitoring
Hourly values to EPA 40 CFR Part 60 / Part 75, permit limits, daily calibration drift, missing-data substitution, quarterly reports and a hash-chained record.
Learn more →CMMSMaintenance management
Asset register linked to live data, preventive maintenance by calendar, run hours or starts, signed work orders, QR/NFC inspection rounds, spares and MTBF/MTTR.
Learn more →Segments
Automotive & parts
Body, paint, assembly and test.
Learn more →Machinery
Machining, assembly and test stands.
Learn more →Metal fabrication
Cutting, welding, heat treat and dust collection.
Learn more →Plastics
Molding and extrusion with mold cooling.
Learn more →Food & beverage
Cold storage, ammonia refrigeration, CIP, steam and wastewater.
Learn more →Systems and equipment
Core: every site of this kind has it. Common: most sites have it. Optional: depends on the site.
Production equipment
Equipment state and output drive OEE.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| CNC machining centerMachinery · Metal fabrication · Automotive & parts | Core | Spindle load · Cycle time · Parts today | |
| Robotic weld cellAutomotive & parts · Metal fabrication | Core | Weld current · Parts today · Safety guard tripped | |
| Injection molding machinePlastics · Automotive & parts | Core | Barrel temp · Mold temp · Cycle time · Shots today | |
| Paint booth & cure ovenAutomotive & parts · Machinery | Core | Booth temp · Booth humidity · Booth pressure · Cure oven temp | |
| End-of-line tester | Common | Tested today · First-pass yield | |
| Line controller (OEE) | Core | OEE · Availability · Performance · Quality · Energy per part | |
| Redundant controller CPU | Common | Running · Redundancy synchronized · Scan time (ms) | |
| Clean-in-place skidFood & beverage | Core | CIP supply temp · Caustic concentration · Supply flow · CIP cycle failed | |
| Overhead crane / hoist | Common | Hook load · Overload | |
| AGV / AMR fleet | Common | Vehicles working · E-stop · Tasks queued | |
| Automated storage and retrieval (AS/RS) | Common | Availability · Crane fault | |
| Palletizer | Common | Rate · Fault | |
| Packaging / labelling line | Common | OEE | |
| Mold temperature controller | Common | Supply temp | |
| Resin dryer | Common | Process air dew point | |
| Granulator | Optional | Motor current · Overload | |
| Stamping press | Common | Tonnage · Die protection tripped | |
| Extruder | Common | Melt pressure | |
| Heat-treat furnace | Common | Furnace temp · Temperature deviation | |
| Induction furnace | Optional | Power · Ground leak (lining) · Cooling flow |
Compressed air & process cooling
Compressed air is often over a tenth of plant power; leaks are the biggest waste.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Air compressor | Core | Discharge pressure · Load · Power draw · Fault | |
| Refrigerated air dryer | Common | Pressure dew point · Pressure drop | |
| Compressed-air header | Core | Header pressure · Air demand · Receiver pressure | |
| Process chiller | Core | Process water supply temp · Process water return temp · Load · Power draw | |
| Process cooling tower | Common | Tower supply temp · Tower return temp · Basin level | |
| Dust collectorMetal fabrication · Machinery · Food & beverage · Automotive & parts | Core | Filter pressure drop · Spark detected | Combustible dust needs spark detection (NFPA 652 / 660). |
| House vacuum system | Optional | Vacuum | |
| Vibration / condition sensor | Common | Velocity RMS | |
| Tank farm level | Common | Level · High-high level · Bund leak |
Steam & hot water
Process heat, washing and space heat.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Steam boilerFood & beverage · Automotive & parts · Plastics | Common | Steam pressure · Firing rate · Drum water level · Low-water cutoff · Fault | |
| Hot-water boiler | Common | Hot water supply temp · Hot water return temp · Firing rate · Flue gas temp · Fault | |
| Heat-recovery chiller / heat pump | Optional | Hot water supply temp · Chilled water supply temp (recovery side) · Power draw · Combined COP | Heat recovery displacing boiler gas — one of the main decarbonization levers. |
| Gas unit heater | Common | Zone temp · Gas valve | |
| Absorption chiller | Optional | CHW supply temp · Crystallization alarm | |
| Plate heat exchanger | Common | Secondary supply temp · Approach · Primary pressure drop | |
| District heating substation | Optional | Secondary supply temp | |
| Hot-water boiler burner control | Common | Firing rate · Burner lockout | |
| Thermal oil heater | Common | Outlet oil temp · Low-flow trip | |
| Steam trap monitoring | Optional | Traps failed · Estimated steam loss | |
| Condensate return unit | Optional | Conductivity |
Refrigeration & cold storage
Ammonia refrigeration and cold rooms in food plants.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Ammonia compressorFood & beverage | Core | Suction pressure · Discharge pressure · Slide valve (load) · Power draw | |
| Evaporative condenserFood & beverage | Core | Condensing pressure · Fan speed | |
| Cooler roomFood & beverage | Core | Room temp · Door left open | |
| Freezer roomFood & beverage | Core | Room temp · Door left open | |
| Ammonia detectorFood & beverage | Core | Ammonia level · Ammonia alarm |
Plant HVAC & ventilation
Comfort, exhaust and make-up air.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Rooftop unit | Core | Supply air temp · Zone temp · Power draw | |
| Exhaust fan | Core | Running · Speed | |
| Air handler | Common | Supply air temp · Duct static pressure | |
| HVLS fan | Optional | Speed | |
| Electric heater | Optional | Heating power · High limit tripped |
Abatement
Paint VOC air permits.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Regenerative thermal oxidizerAutomotive & parts · Machinery · Plastics | Core | Combustion chamber temp · Inlet solvent (LEL) · Bypass damper open | |
| Combustible gas detectorAutomotive & parts · Machinery | Core | Combustible gas (LEL) · Gas alarm |
Water & wastewater
Food plants make high-COD wastewater needing pretreatment.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| pH neutralization system | Common | Effluent pH · Flow | |
| Final effluent monitorFood & beverage · Automotive & parts | Common | Discharge flow · Discharge pH · COD | |
| Domestic water booster | Common | Discharge pressure · Flow | |
| Cooling tower chemical treatment | Common | Conductivity · Chemical drum low | |
| Side-stream filter | Optional | Filter differential pressure | |
| Water tank / reservoir level | Common | Level · Low level · Overflow level | |
| Water softener | Common | Outlet hardness · Salt low |
Power & sub-metering
Meter by line to get energy per part.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Main switchgear meter | Core | Plant power · Energy today · Power factor | |
| Transformer | Core | Winding temp · Load · Over-temperature alarm | Dry-type transformers. |
| Motor control center | Common | MCC load · Current · Power factor · Current THD | |
| Area energy meter | Core | Area power · Energy today · 15-min demand · Power factor | Sub-metering by workshop or system for energy analysis and cost allocation. |
| Power quality meter | Common | Voltage THD · Current THD · Voltage sags today · Sag / interruption event | Voltage sags are a common hidden cause of trips. |
| Natural gas meter | Common | Natural gas flow · Heat input (1,037 BTU/scf) · Gas today (scf) | Natural gas in scfh, converted to BTU/h by heating value. |
| Generator | Optional | Running · Output power · Fuel tank level · Starting battery voltage · Not in AUTO | |
| Rooftop solar inverter | Optional | Solar output | |
| EV chargers | Optional | Charging power | |
| Ring main unit | Common | SF6 low · Fault passage indicator | |
| Microgrid controller | Optional | Grid exchange · Islanded | |
| Wind turbine | Optional | Output · Fault | |
| Active harmonic filter (APF) | Common | After current THD · Unit load · Modules in fault · Fan fault | |
| Passive (tuned) harmonic filter | Common | After current THD · Capacitor current, measured / rated · Resonance alarm | |
| Hybrid harmonic filter | Optional | After current THD · Unit load · Resonance alarm | |
| Static var generator (SVG / STATCOM) | Common | PF after · Unit load · Modules in fault | |
| Automatic capacitor bank | Common | Power factor · Capacitor current, measured / rated · Resonance alarm · Switching operations today | |
| Fixed capacitor bank | Optional | Reactive output · Fuse blown · Capacitor current, measured / rated | |
| Power factor controller | Common | Power factor · Under-compensated · Over-compensated | |
| Phase unbalance compensator | Optional | Current unbalance after · Unit load | |
| Voltage stabilizer / AVR | Optional | Output voltage · On bypass | |
| Phase-shifting (harmonic-mitigating) transformer | Optional | Winding temp · Primary current THD | |
| Line / DC-link reactor | Optional | Reactor temp | |
| Sine-wave filter | Optional | Output voltage THD · Filter temp | |
| dv/dt filter | Optional | Filter temp | |
| Active front end (AFE) drive | Optional | Input current THD | |
| Switchgear wireless temperature | Common | Hottest point · Phase difference |
Life safety Monitor only
Monitor only.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Fire alarm panel | Core | Fire alarm · Supervisory signal · Trouble signal | Monitor only (NFPA 72). |
| Fire pump | Common | Running · System pressure · Power phase failure | |
| Sprinkler riser | Common | Riser pressure · Waterflow alarm · Valve tamper | |
| Smoke exhaust fan | Common | Running · Damper not proven | Smoke exhaust or stair pressurization fans; monitor only. |
Security & video Monitor only
Camera and door status, and video linkage: cameras are linked to areas, devices and alarm rules; on an alarm the gateway takes an ONVIF snapshot and attaches it to the alarm, with a live-view link to the NVR/VMS. Core never contacts a camera.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Video camera | Common | Online · Recording · Motion detected · Video analytics alarm · Tamper (blocked or moved) | Status via the VMS (Milestone, Genetec…); on an alarm the gateway takes an ONVIF snapshot and attaches it to the alarm — Core never contacts a camera. |
| Access-controlled door | Common | Door open · Door held open · Door forced | Door events can drive camera linkage. |
| Network switch (SNMP) | Common | Ports down · PSU fault |
Life-safety equipment (fire alarm, gas detection, emergency power transfer) and protection devices are monitored only. FacilityOS never sends them commands.
Standards and compliance
| Standards and compliance | Notes |
|---|---|
| ISO 50001 | Energy management systems. |
| ISO 22400 | Key performance indicators for manufacturing operations management, including OEE. |
| ANSI/ISA-95 | Enterprise-control system integration. |
| NFPA 33 | Spray application using flammable or combustible materials. |
| NFPA 652 / NFPA 660 | Fundamentals of combustible dust (NFPA 660 consolidates the industry dust standards). |
| IIAR 2 | Standard for safe design of ammonia refrigeration systems. |
| FDA FSMA | Food Safety Modernization Act (preventive controls). |
| OSHA 29 CFR 1910.147 | Control of hazardous energy (lockout/tagout). |
| IEC 62443 | Industrial automation and control system security. |
Standards are listed with what they cover; numeric values are typical figures, not requirements for every site. FacilityOS supports your compliance work; it does not certify a site.
KPIs the platform tracks
| KPIs the platform tracks | Notes |
|---|---|
| OEE | Availability × performance × quality. |
| Energy per part | Line kWh ÷ good parts. |
| Compressed-air specific power | kW per 100 cfm. |
| Peak demand | 15-minute demand peak. |
Reports
| Reports | Notes |
|---|---|
| OEE & downtime report | Downtime by machine and cause. |
| Energy & energy-per-part report | Energy by line and per part. |
| Air permit records | RTO temperature and bypass records. |
How we deliver
We can take a General & discrete manufacturing project from survey and design through procurement, installation, commissioning and training — all of it, or only the stages you need.
- Site survey & needs assessment
- Solution design
- Procurement
- Installation
- Commissioning & acceptance
- Training
- Go-live & support
Demo site
Greenville Assembly Plant
A two-shift auto-parts plant — machining, robotic welding, molding and paint — with compressed air, process cooling and steam.
Open the Greenville Assembly Plant demo site to see this industry with simulated live data: process graphics, video wall, alarm drills and remote adjustment.
Try the live demo