POP
Point of Production
Capture real-time production data at the source with IoT-connected shop floor terminals and sensor integration.
VEXPLOR POP provides shop floor data collection terminals and IoT gateway services that capture production events, machine status, and operator inputs in real time. As the data foundation for MES, SPC, and Digital Twin systems, POP ensures accurate, timely, and complete production data from the point where value is created.
Non-Standard (Before)
Non-Standard (Before)
- Production counts recorded on paper at end of shift
- Machine downtime manually estimated from memory
- No real-time connection between machines and business systems
- Data entry delays causing hours of information latency
Standardized (After)
Standardized (After)
- Automated production counting from machine signals and sensors
- Real-time downtime detection with reason code capture by operators
- Direct machine-to-cloud data pipeline via OPC UA and MQTT
- Sub-minute data latency from shop floor event to dashboard
POP Data Collection Flow
Sensor Connection
Connect machines via IoT gateways using OPC UA, MQTT, Modbus, and digital I/O protocols.
Data Capture
Automatically collect production counts, cycle times, machine states, and process parameters.
Operator Input
Touchscreen terminals for downtime reasons, quality checks, scrap reporting, and shift notes.
Data Streaming
Stream processed data to MES, SPC, Digital Twin, and analytics platforms in real time.
Key POP Capabilities
Machine Connectivity
Universal IoT gateway supporting OPC UA, MQTT, Modbus TCP/RTU, and digital I/O interfaces.
Auto Production Counting
Automated piece counting from machine signals with cycle time analysis and target tracking.
Downtime Detection
Real-time machine status monitoring with automatic state detection and operator reason coding.
Shop Floor Terminals
Ruggedized touchscreen terminals for operator data entry, work order tracking, and visual management.
Edge Computing
Local data processing and buffering ensuring zero data loss even during network interruptions.
Real-Time Streaming
Sub-second data streaming to cloud platforms via MQTT with automatic reconnection and buffering.
Compliance & Standards
ISA-95
Enterprise-control system integration defining shop floor data collection architecture.
POP Integration Ecosystem
POP serves as the data collection foundation, feeding real-time production data to MES for execution management, Digital Twin for virtual modeling, and SPC for statistical process monitoring.
Why VEXPLOR POP
| Traditional | VEXPLOR | |
|---|---|---|
| Connectivity | Custom integration per machine model | Universal gateway supporting all major protocols |
| Deployment | Weeks of wiring and configuration | Plug-and-play setup in hours per machine |
| Reliability | Data loss during network outages | Edge buffering with guaranteed delivery |
| Legacy Support | Only connects to modern machines | Retrofit any machine regardless of age or brand |
Connectivity
Deployment
Reliability
Legacy Support
Connect Your Shop Floor
Start collecting real-time production data in hours, not months. Connect any machine with plug-and-play IoT gateways.