Plant SCADA Uptime Monitoring Agent
Monitors plant SCADA, PLC network, and industrial control system uptime and connectivity, alerting IT and operations before a system fault disrupts manufacturing production.
Plant IT and OT (operational technology) teams responsible for keeping SCADA systems, PLC networks, and industrial control infrastructure running are often notified of a problem only after production has already stopped, because there is no continuous, automated view of control system health separate from the production floor's own downtime logs
Diagnosing whether a stoppage originated from a network fault, a PLC firmware issue, or a SCADA server problem typically requires manually pulling logs from multiple disconnected systems after the fact
This agent continuously monitors the health, connectivity, and performance of SCADA servers, PLC network segments, and HMI stations across the plant, detecting early warning signs such as network latency spikes, failed heartbeat checks, or server resource exhaustion before they cause a production-impacting outage
It correlates control system incidents directly with any resulting line stoppage to give IT and operations a shared, fast diagnosis
The agent polls SCADA server health metrics, PLC network heartbeat and latency data, and HMI station connectivity status on a continuous basis, applying anomaly detection to identify degrading performance before a hard failure occurs. When an incident does occur, it automatically correlates the control system event timeline against any concurrent production line stoppage recorded in the MES, producing a unified incident timeline. Alerts are routed to IT/OT support with the affected system, likely cause, and correlated production impact attached.
Control System Health Monitoring
- Poll SCADA server resource and performance metrics continuously
- Monitor PLC network heartbeat, latency, and packet loss
- Track HMI station connectivity and responsiveness
- Establish baseline performance per system for anomaly comparison
Early Warning Detection
- Detect degrading performance trends before a hard failure occurs
- Flag network latency spikes or intermittent PLC communication drops
- Identify SCADA server resource exhaustion trending toward failure
- Prioritize warnings by criticality of the affected system
Incident Correlation
- Detect confirmed control system incidents (outage, fault, disconnect)
- Cross-reference the incident timeline against MES production stoppage logs
- Identify which lines or work centers were impacted by the incident
- Estimate production time and cost impact of the incident
Alerting & Resolution Tracking
- Alert IT/OT support with affected system and likely cause
- Route production-impacting incidents to plant operations simultaneously
- Track incident resolution time and root cause once diagnosed
- Compile a recurring control system reliability report