Omni-Lox — Factory Health Platform

🏭Factory Health

78%

2 machines need attention

Action Required

⚙️Machines Running

7/7

All machines operational

All Running

⚡Site Energy Today

312kWh

Est. £87.36 at £0.28/kWh

Normal

⚡Static Bars Active

26/28

2 bars need cleaning

Clean Required

Active Alerts 2

⚠️

PS2

Static bars overdue for cleaning — efficiency falling on bars 2 and 3

Clean Due

⚠️

SL2

Bar clean overdue — check at next roll change

Clean Due

All Clear

All systems operating normally

Static Level

3.1 kV

Limit: 5.0 kV

⛔️

Problem

Static bars are overdue for cleaning

›

📘

What to do

Clean bars at next machine stop — contact your engineer

›

Static Monitor — Live

Within Limit

Highest Zone

2.1 kV

0⚠ 5kV

Zone A		1.8 kV
Zone B		2.1 kV
Machine Stop		No

PLC & Comms

Run Mode

Parameter		Value
PLC Status		Run
EtherNet/IP		Connected
Machine Running		Yes
Line Speed		28 m/min
Omni-IO (CC100)		Online
Manager IQ		Active
Poll Rate		250 ms

Energy & Predictive

Roadmap

Parameter		Value
Energy Today		62 kWh
Peak Demand		14.2 kW
Motor Vibration		No sensor
Bearing Temp		No sensor

Vibration sensors — Sensoteq wireless. Available from Omnitech.

Site Energy

312 kWh

Bars Active

26 / 28

Clean Warnings

2 machines

Network

14 / 14

One platform — four monitoring disciplines

All on one screen, one system, one support contract.

Available from Omnitech

⚡

Energy Monitoring

CT meters · 3-phase · ESOS

£1,240

/ month

Site energy cost
tracked automatically

Site energy today312 kWh

Peak demand68.4 kW

Highest machinePS2

vs last month↓ 4%

ESOS Phase 3

Per-machine metering

Shift reporting

💨

Compressed Air

Pressure · Flow · Leak detection

£380

/ month

Estimated air cost
currently unmetered

Main line pressure6.2 bar

Flow rate42 l/min

Leak detectedNone

Cost per shift£12.60

Leak detection

Cost per shift

Pressure trending

📳

Vibration & Predictive Maintenance

Sensoteq wireless · Bearing health

84%

of limit

Rewind motor bearing
trending upward

Coat head motor1.2 mm/s

Rewind motor3.8 mm/s ↑

Drive motor0.9 mm/s

Wireless sensors

Bearing temp

Failure prediction

🌡️

Temperature Monitoring

Cabinet cooling · Motor temps

PS1 cabinet28°C — OK

PS2 cabinet44°C — Warm

Coat head motor38°C — Normal

Rewind motor61°C — Monitor

Cabinet limit60°C

ATEX safe

Cabinet cooling

Motor protection

🔗

Remote Access & Alerts

Web app · Email & SMS · SCADA

Remote web accessflexcon.omnilox.co.uk

Email alertsActive

SMS alertsActive

SCADA data feedModbus TCP

ERP integrationOn request

5G connectivity

Any device

Omni-Comms

📊

Reporting & Compliance

Shift reports · ESOS · Audit trail

£2,840

saved

Estimated saving this year
from static control insight

Bar clean compliance94%

Unplanned stops MTD2

Energy reportAuto-generated

PDF export

Shift handover

ESOS ready

AI Insights

Pattern detection and predictive recommendations — updated continuously as data accumulates

🤖 AI Engine Active

Phase 3

High Priority

1

Immediate action

Medium Priority

3

Monitor this week

Estimated Annual Saving

£4,200

If all actions taken

Confidence Level

87%

Based on 90 days data

⚡

High Priority

PS2 · Static Control

Confidence: 94%

Bar 2 efficiency degrading 3× faster than historical average

Ionisation efficiency on BAR 02 (Coat Head) has dropped from 92% to 48% over 18 days — significantly faster than the usual 45-day clean cycle for this position. Pattern matches contamination from solvent misting. Recommend immediate clean rather than waiting for the scheduled interval.

Est. Annual Impact

£1,800

in waste if ignored

Detected: pattern analysis over last 90 days · Updated hourly

📈

Medium Priority

SL2 · Static Control

Confidence: 88%

Clean interval should be reduced from 14 to 10 days on Slitter 2

Analysis of 6 cleaning cycles shows SL2 consistently reaches warning threshold at day 10–11, suggesting the 14-day interval is too long for this machine's duty cycle. Reducing the interval would prevent static warnings and maintain higher average efficiency.

Est. Annual Impact

£640

efficiency improvement

Based on 6 complete clean cycles · 90 days of data

🌡️

Medium Priority

PS2 · Temperature

Confidence: 82%

PS2 control cabinet temperature rising trend — monitor for cooling issue

Cabinet temperature has increased from 31°C to 44°C over the past 3 weeks. Rate of increase suggests either filter blockage or cooling fan degradation. If trend continues, cabinet will reach 60°C limit within 8–10 days. Temperature sensors available as part of Phase 2 expansion.

Est. Time to Limit

8 days

at current trend

Available with Phase 2 temperature sensors installed

✅

Positive Finding

PS1 & TC1 · Static Control

Confidence: 96%

New cleaning procedure is working — PS1 efficiency up 8% since last month

Since the updated cleaning procedure was introduced on PS1 and TC1, average bar efficiency has increased from 88% to 95%. The rate of degradation between cleans has also slowed, suggesting less contamination reaching the bars. Recommend rolling this procedure out to PS2 and SL lines.

Est. Annual Saving

£1,760

if rolled out site-wide

Detected: efficiency trend analysis · Last 30 days vs previous 30 days

Bars Active

26/28

2 bars need cleaning

Clean Warnings

2

PS2 and SL2

Avg Efficiency

87%

Across all active bars

Highest Static

3.1 kV

PS2 — limit 5.0 kV

PS1

4/4 Active

Efficiency94%

Static level1.8 kV

Last clean4 days ago

PS2

Clean Due

Efficiency48%

Static level3.1 kV

Last clean18 days ago

TC1

3/3 Active

Efficiency95%

Static level1.2 kV

Last clean6 days ago

TC2

3/3 Active

Efficiency97%

Static level0.9 kV

Last clean5 days ago

SL1

3/3 Active

Efficiency93%

Static level1.4 kV

Last clean3 days ago

SL2

Clean Due

Efficiency46%

Static level2.4 kV

Last clean21 days ago

SL3

3/3 Active

Efficiency94%

Static level1.1 kV

Last clean2 days ago

🤖

AI Insight

Static Control · Pattern Detected

Confidence: 94%

PS2 Bar 2 degrading 3× faster than historical average — recommend immediate clean

Ionisation efficiency has dropped from 92% to 48% in 18 days vs the usual 45-day cycle. Pattern matches solvent misting contamination. Estimated annual impact if ignored: £1,800.

Site Energy Today

312 kWh

Est. £87.36 at £0.28/kWh

Peak Demand

68.4 kW

06:00 shift start

vs Yesterday

↓ 4%

296 kWh yesterday

This Month

£1,240

Projected energy cost

Machine Energy Breakdown — Today

All values estimated — CT meters required for live data

Machine	Type	Est. kWh	Est. Cost	% of Site
PS1	Primary Coating	68 kWh	£19.04	22%
PS2	Primary Coating	89 kWh	£24.92	29%
TC1	Top Coat	42 kWh	£11.76	13%
TC2	Top Coat	38 kWh	£10.64	12%
SL1–SL3	Slitters	75 kWh	£21.00	24%

🤖

AI Insight

Energy · Pattern Detected

Confidence: 88%

PS2 consuming 22% more energy than PS1 for equivalent output — investigate efficiency gap

PS2 is running at higher power draw despite similar line speeds. Pattern suggests drive inefficiency or additional load. Estimated annual saving if resolved: £2,100. CT meters required for confirmed live data.

Current Flow

42.1 L/min

Within normal range

Line Pressure

6.1 bar

Nominal: 6.0–6.5 bar

Leak Status

✓ No Leak

Within ±15% of baseline

Est. Monthly Cost

£380

Currently unmetered

Main Supply Line

6.1 bar

0 bar8.0 bar max

Flow42 l/min

Compressor hours6.4 hrs

Filter Status

OK

CleanReplace at 100%

Filter ΔP760 Pa

Next service~42 days

Leak Detection

✓ No Leak

Flow is within ±15% of baseline (43.2 L/min). No leak signature detected in last 24 hours.

Baseline flow43.2 l/min

Leak threshold+15%

🤖

AI Insight

Compressed Air · Usage Pattern

Confidence: 81%

Air consumption 18% higher on night shift — possible overnight leak or equipment left running

Flow data shows a consistent pattern of elevated consumption between 22:00 and 06:00 when machines should be idle. Estimated annual cost of overnight waste: £840. Recommend pressure test after shutdown.

Sensors Active

3/3

All sensors reporting

Highest Reading

3.8 mm/s

Rewind motor — rising

ISO Alert Limit

4.5 mm/s

ISO 10816 Zone B/C limit

Predicted Failure

18 days

Rewind motor at current trend

Coat Head Motor

Healthy

Sensoteq wireless · Bearing A

1.2 mm/s

0Warn 2.0Alert 4.5

Bearing temp38 °C

TrendStable

Rewind Motor

Rising

Sensoteq wireless · Bearing B

3.8 mm/s

0Warn 2.0Alert 4.5

Bearing temp61 °C

Trend↑ Rising — monitor

Drive Motor

Healthy

Sensoteq wireless · Bearing C

0.9 mm/s

0Warn 2.0Alert 4.5

Bearing temp34 °C

TrendStable

🤖

AI Insight

Vibration · Predictive Alert

Confidence: 91%

Rewind motor bearing approaching alert threshold — plan maintenance within 18 days

Vibration rising at 0.12 mm/s per day. At this rate the ISO alert limit (4.5 mm/s) will be reached in approximately 18 days. Bearing temperature also elevated at 61°C. Last bearing replacement was 14 months ago. Estimated cost of unplanned failure: £8,400 in downtime.

⚙️ Demo Settings — Changes apply instantly across all screens.

📍

Site & Customer

Customer Name

Site / Location

Platform Description

🏭

Machine Names

PS1 Description

PS2 Description

TC1 Description

TC2 Description

⚡

Static Thresholds

Safety Limit (kV)

Warning Level (kV)

Bar Clean Interval (days)

🔔

Alerts & Billing

Alert Email

Alert SMS

Power Tariff (£/kWh)

Changes apply instantly across all screens