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Production Monitoring & Reporting
Real-Time Visibility and Data-Driven Insights for Manufacturing Efficiency
At KAMAPS, we provide advanced production monitoring and reporting systems designed to give manufacturers and process operators total control over operational performance. By capturing real-time production data, our systems help you track output, detect inefficiencies, and make informed decisions to meet productivity targets, minimise losses, and optimise scheduling.
Our scalable solutions are ideal for discrete manufacturing, continuous processing, and batch-based industries, enabling businesses across the United Kingdom to maintain operational excellence and improve transparency across departments.
What Is Production Monitoring and Reporting?
Production monitoring is the continuous collection and analysis of real-time data from machines, processes, and production lines. Combined with automated reporting tools, these systems deliver actionable insights into performance metrics such as:
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Output per shift or machine
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Downtime frequency and duration
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Cycle time efficiency
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Scrap and rework rates
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Machine availability and utilisation
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Operator performance
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Loss tracking and bottleneck identification
The result is a measurable increase in productivity, traceability, and decision-making speed—all from a centralised platform with full remote access.
Our Production Monitoring Services Include:
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Custom design and deployment of machine monitoring systems
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Real-time data acquisition via PLC, sensors, or IIoT devices
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Integration with MES, SCADA, and ERP platforms
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Custom dashboards for KPIs, alerts, and shift summaries
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Historical data logging and visualisation tools
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Remote access via cloud or secure VPN
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Automated OEE (Overall Equipment Effectiveness) calculation
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Scheduling dashboards with live production status
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Customised reporting tools for daily, weekly, and monthly summaries
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Mobile and tablet compatibility for on-the-go access
Technologies and Systems We Integrate
We work with a wide range of industry-leading systems and protocols, including:
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PLC and HMI platforms (Siemens, Allen-Bradley, Mitsubishi, Schneider Electric)
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SCADA systems such as Ignition, FactoryTalk, and WinCC
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MES (Manufacturing Execution Systems)
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Industrial communication protocols including Modbus TCP, PROFINET, OPC UA, MQTT
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Smart sensors for production counters, part detection, reject rates, and energy consumption
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Cloud platforms for remote access, alerts, and reporting
These systems are custom-configured to your plant layout, production model, and reporting preferences.
Key Features of Our Monitoring & Reporting Systems
Real-Time Production Dashboards
Monitor every machine and production line in real time. Track progress toward shift and daily production targets, view equipment utilisation, and analyse process bottlenecks instantly.
Downtime & Loss Tracking
Log every instance of machine stoppage, changeover delay, or unplanned event. Classify losses by root cause to support continuous improvement and OEE tracking.
Automated Reporting & Analytics
Generate and schedule reports with key operational insights delivered to your inbox or dashboard. Compare performance across shifts, machines, or locations with visual graphs and charts.
Shift Scheduling & Task Allocation
Assign shift plans, set production targets, and align staffing and equipment availability with real-time scheduling tools.
Remote Data Access & Notifications
Access live data and reports from any web-enabled device. Receive alerts for critical conditions such as downtime, output deviations, or underperformance.
Common Applications of Production Monitoring & Reporting
Output Tracking for High-Speed Manufacturing Lines
Description: Use of sensors and counters to monitor output volume, reject rates, and downtime across packaging, bottling, or assembly lines.
Benefits:
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Improved output accuracy and process control
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Quick identification of underperforming equipment
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Supports shift performance evaluation and productivity improvements
Batch Reporting in Food, Pharma, or Chemical Processing
Description: Integration of batch start/stop tracking with material usage, cycle times, and traceability logs.
Benefits:
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Ensures process consistency and traceable documentation
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Aligns production records with quality control protocols
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Simplifies reporting for audits and client delivery verification
Remote Monitoring for Multi-Site Operations
Description: Cloud-based dashboards showing the real-time performance of geographically separated production facilities.
Benefits:
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Centralised management oversight across all locations
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Enables benchmarking and best-practice sharing
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Reduces the need for physical site presence and manual reporting
Advantages of Choosing KAMAPS
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Extensive experience in production data systems integration for UK manufacturers
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Real-time solutions that support OEE, downtime tracking, and quality control
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Seamless connectivity to your existing control, MES, or ERP infrastructure
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Mobile and cloud-based systems for remote operations management
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User-friendly dashboards tailored to engineers, operators, and managers
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Ongoing support for system upgrades, training, and performance reviews
Transform Production Visibility Into Actionable Insights
With increasing pressure to reduce waste, maximise productivity, and meet tight deadlines, having real-time production data at your fingertips is essential. Our monitoring and reporting systems give you the tools to measure performance, eliminate guesswork, and build more agile, responsive operations.
Speak with Our Engineers
Let’s discuss how production monitoring can support your operations. Contact us for a free consultation, system demo, or site assessment.