Showroom Spotlight Series: Machine Analytics Tool (MAT)
- info2636801
- Dec 29, 2025
- 5 min read
Updated: Jan 29
Real-Time Visibility for Modern Production
MAT delivers comprehensive production visibility by combining real-time monitoring, detailed machine data recording, and intuitive performance analysis.
It empowers you to quickly identify downtime causes, track quality and scrap trends, and optimize scheduling—all through clear reports and integrated audio/video insights for smarter, more efficient operations.
Real-Time Machine Monitoring
Monitor your plant in real time with a 3D digital twin, live telemetry, and instant alerts. Stay in control with full visibility into machine status and events.
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Real-Time Monitoring: Track performance data as it happens
Alarms & Alerts: View active and past alarms for quick response
Machine Status: Quickly spot downtime and trends visually
3D Digital Twin: Navigate the virtual plant and interact with live data
Lean Analytics
Quickly identify and resolve productivity bottlenecks to increase efficiency
Track OEE, pinpoint bottlenecks, and trace production events to boost efficiency. Analyze downtime, scrap, and changeover times to support performance-based maintenance contracts
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OEE Monitoring: Analyze overall efficiency and uncover root causes of loss
Production Tracking: Monitor processes and access detailed performance
Downtime Analysis: Identify and break down causes of lost production time reports
Scrap Reduction: Find quality issues and cut waste at the source
Machine Recorder
Simplify process diagnostics with MAT's comprehensive machine data recording.
Explore PLC variable trends alongside machine status, alarms, and operator actions. Choose your time window and zoom in for fast, focused analysis
Cycle Exploration: Track and compare process data for each machine cycle. Spot drifts, review full cycle history, and filter by recipe, batch, or other key factors
Resource Consumption Management
Efficiently manage energy and resource consumption for sustainable machinery operations.
Track how machines consume electricity, air, water, gas, and raw materials. Use AI to calculate a sustainability index and uncover cost drivers.
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Monitor: Measure absolute and per-unit consumption for all key inputs
Optimize: Get AI-driven suggestions to reduce waste and improve efficiency
Analyze: Spot patterns linked to higher usage, like product type or shift
Configurable Notifications and Reports
Receive instant notifications and automatic reports on critical events with MAT
Save time with automated alerts, actions, and reports—no constant monitoring required. MAT triggers notifications or PLC commands based on conditions you define, like high air usage or low OEE.
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Custom Alerts: Set your own triggers using variables, KPIs, and logic. Define recipients and response actions
Automated Actions: Go beyond alerts—automatically execute PLC commands when thresholds are crossed
Scheduled Reports: Send fully customizable reports on a schedule using HTML5 templates
Operator Empowerment
Identify knowledge gaps and enhance training effectiveness with MAT
Evaluate operator skill levels and identify training needs based on real machine interactions. MAT tracks behavior patterns—like button presses and parameter changes—and compares them to KPIs such as OEE or defect rates.
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Skill Assessment: Detect knowledge gaps based on actual machine use
Targeted Training: Create custom training paths by operator, machine, or process
Lower Training Costs: Focus resources where they’re needed most
Skill Digitalization: Capture and standardize operator expertise digitally
Health Monitoring
Use AI for proactive maintenance to prevent machine downtime well in advance.
Prevent failures and cut downtime with AI-powered anomaly detection. Monitor component health and act early—weeks before breakdowns occur—across your entire machine fleet.
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Recognize & Anticipate: MAT learns normal behavior and flags anomalies automatically
Analyze Trends: Track component health over time to spot risks early Cycle Comparison: Compare normal vs. abnormal cycles to find root causes fast
Real-time Cost Analysis
Analyze production costs in real time and uncover hidden patterns to optimize margins
Track real-time costs across energy, materials, waste, downtime, and more. Uncover hidden drivers and boost margins
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Cost Breakdown: Get detailed reports on unit cost, total production, and consumables used—down to quantity and cost per unit
Pattern Detection: Identify costly parameter combinations, supplier impacts, and sustainability trade-offs
Smart Maintenance
Automate maintenance schedules and spare parts ordering for smarter operations
Manage all maintenance tasks in one place—track component life, auto-order spare parts, schedule activities, log interventions, and access docs
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Maintenance Status: See current condition and remaining life of components
Bill of Materials: Auto-generate spare parts lists for upcoming maintenance
Planning: Schedule and coordinate inspections efficiently
Fault Analysis: Identify failure causes and component lifetimes across your fleet
Global Machine Access
Instantly access any connected machine worldwide from a local plant with MAT
Instantly access all connected machines—locally or globally. Compare performance across your entire fleet to quickly spot machines needing attention.
Event-Based Multimedia Recording
Capture video and photo sequences during specific machine events with MAT
See your production line live, anywhere. MAT links video streams with telemetry and alarms for real-time, visual monitoring—like being on site remotely.
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Event-Triggered Recording: Connect RTSP cameras to MAT EDGE to capture video during alarms or threshold breaches, paired with machine data for full diagnostics
Quality Inspection Capture: Automatically import and archive images from vision inspection systems tied to product rejects for easy review alongside other data
Digital Documentation
Share machine documentation digitally with customers for easy access
Quickly access all machine manuals, datasheets, maintenance guides, drawings, and more in digital format.
Production Order Management
Import and execute production plans directly on machines with MAT
Manage production orders seamlessly by transferring them to machine PLCs. Integrates with your ERP to import plans, and operators can access it via web browsers on tablets or PCs. Production order fields are fully customizable.
Built to Fit Your Operation
MAT is designed to sit comfortably inside existing environments rather than forcing a full rebuild of your tech stack.
Key advantages include:
Modular and scalable – Start with a single line and expand across plants as needed.
Flexible deployment – Edge, on-premise, cloud, or hybrid, depending on IT and data policies.
Hardware-agnostic – Works with a wide range of industrial devices and controls.
Enterprise connectivity – Connects with ERP, MES, CRM, and BI tools to align production data with business data.
MAT is built to answer the core questions of any production environment:
How are my machines running right now?
Where are we losing time, performance, or quality?
What issues are emerging before they become downtime?
Cybersecurity
Commitment to information security: The MAT architecture is consistently subjected to assessments and penetration tests conducted by an independent, specialized partner. This ensures compliance with rigorous industrial security standards.
Segregation of machine and customer data
Strong authentication and role-based access
Regular security testing and hardening
See It in Action
At the IMS Showroom in Grand Rapids, Michigan, visitors can see MAT connected to real equipment and sample data streams, including:
Live production dashboards
Predictive and condition-based insights
Virtual and XR-based views of equipment and processes
See it in person at the IMS Showroom in Grand Rapids, MI or schedule a virtual meeting with us to learn more
