Frequently Asked Questions about Production Monitoring

There is a push-button on the node enclosure that will zero the count and accumulated times.  Up to four automatic resets can be configured for shift changes or other time-based reset needs. Users with access can also reset remotely through our software.

The electro-optic sensors that detect the boxes require wall power to “watch” all the time. The data from the device node is transmitted wirelessly to the gateway.

Yes. The production monitors each have logic to separate downtime from running time. Each downtime event is timed by the sensor. You can set telephone, text, and email alerts if the time down exceeds a certain amount of time. You can set that downtime alarm limit in the software configuration screen. You can have the message sent to anyone. You can set alerts for any of the other values that a Leap production monitor tracks.

Common Applications for Production Monitoring

  • Wireless production counter
  • Wireless downtime monitor
  • Wireless downtime alert system
  • Line rate sensor wireless
  • Line counter wireless sensor
  • Downtime alert system
  • Wireless sensor for downtime
  • Wireless sensor for production count
  • Wireless pulse counter
  • Process stop counting
  • Equipment utilization monitoring
  • Encoder monitoring
  • Liquid flow monitoring
  • Material presence tracking

The Perfect System for Smart Factory Implementations

Production tracking is a critical component of Industry 4.0, enabling real-time visibility, efficiency, and adaptability in your operations. We designed Leap monitoring systems with the specific, demanding needs of manufacturers in mind.

Sensors & Industrial Internet of Things (IIoT) devices for every production scenario

  • Track discrete counts, intermittent and continuous processes, as well as flow metering and web converters.
  • Use photoeyes, proximity switches, encoders, current switches, or virtually any discrete or analog sensor to capture data at every stage.

Simple Installation

Leap sensors are built pre-configured to run right out of the box.  Most sensors install in 5 minutes or less.

  • Just mount the transceiver node, turn it on, and start collecting data- no complex wiring or programming.
  • Introduce new Leap tracking technologies alongside existing systems to minimize disruption and allow quick incremental benefits. Also great for temporary installations for testing or Kaizen workshop events.

Connectivity & Data Integrity

Leap production sensors securely connect using wireless communication to gateways and software for access by operators and management.

  • Choose where your data goes- keep it local, send it to the cloud, share it with other systems such as PLC or SCADA, download it, display it- the options are endless for seamless data flow.
  • All data transmissions are verified through two-way communication handshakes – the same encryption technology used by banks.
  • Transmissions avoid interference with other data systems including plant Wi-Fi networks.
  • In the rare event that data cannot be transmitted from a sensor to our gateway, the sensor node stores the time-stamped data until it can be transmitted, so that no data is lost.

Edge Processing

Each Leap production sensor uses a micro-processor to immediately analyze incoming signals and calculate key metrics.

  • Separate downtime from running conditions, count stops, and calculate machine utilization or Overall Equipment Effectiveness (OEE).
  • Specialized firmware unique to the monitoring application: identify events and summarize data for any manufacturing situation.

Integration with Existing Systems

  • ERP/MES Integration: Sync production tracking with Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES) for end-to-end visibility.
  • Flexible Data Options – It’s your data- use it the way that is best for you!
    • Use our Leap software to view and display your data so that it meets your goals.
    • Use Leap sensors to collect data for other software you already have for tracking and managing production.
  • Legacy Equipment Compatibility: Leap production sensors are perfect for connecting older machines to modern tracking systems – without expensive wiring and time-consuming custom programming.

Real-Time Monitoring & Visualization

  • Customizable dashboard displays give operators and managers insight into real-time KPIs like OEE (Overall Equipment Effectiveness), cycle times, stop counts and downtime.
  • Set up automated alerts for extended downtime or other critical situations.

Data Accuracy & Granularity

  • Timestamp Precision: Every data transmission includes a timestamp to enable detailed record-keeping and analysis.
  • Granular Tracking: Track at the unit, batch, or lot level depending on the product needs. Set up as many sensors as you need to track all the value streams of your manufacturing process.
  • Access Detailed Data for Analysis and Reporting: Download data from the Leap system into a .csv for analysis & continuous operations improvement. Use the data to highlight long downtime events, or to track minor stops. Focus your organization on the data that matters most.

Scalability & Flexibility

  • Modular Architecture: Leap systems can scale with production volume or new product lines.
  • Custom Workflows: Firmware for different production sensor types allow for flexible tracking logic to accommodate different manufacturing processes.

Compatible with Other Leap Sensors

  • Predictive Maintenance: Add motor monitoring to predict failures before they happen.
  • Condition Monitoring: Add temperature, pressure, and humidity sensing to key equipment, processes and storage locations to track conditions and alert personnel when abnormalities occur.
  • Same platform for All Uses: Connect all your wireless sensors, regardless of function, to the Leap gateway for easy access to data in one place, or easy sharing with other software.