ZentONE® - Real OEE
Without Stopping Production
Without Stopping Production
Over 80% of factories manually measure their machine performance.
This results in a 20-30% capacity loss due to invisible downtime and micro-stops.
ZentONE eliminates this invisibility without touching the PLC or stopping the line, installation in hours, local data in SQL database, operational dashboards, ERP and AI integration
Measurable results from the very first machine:
Typical OEE increase of 15-25% on real lines (without new machinery)
Quick installation with no machine downtime
100% on-premise → data never leaves your network
Compatible with industry-standard signals (24VDC, 0-10V, 4-20mA, Modbus)
Based on Edge and Single Pair Ethernet technology from Perinet GmbH
Write an email to ZentONE@ZentinelMDS.com for a demonstration of ZentONE
Install a ZentONE system to measure the performance of your first machine and obtain objective, continuous information about its production.
Measure production, rejects, and downtime in real time.
Automatically calculate Overall Equipment Effectiveness (OEE).
Record and visualize machine data locally, without relying on the corporate network or cloud.
Use Artificial Intelligence with ZentONE data to quickly identify opportunities for improvement on that machine.
ZentOPS allows you to link real-time information from ZentONE with your company's ERP system.
Send and receive order information directly to your ERP using standard communication mechanisms.
Track product and material batches
Enable operators to select and manage active production orders at a digital workstation.
Automate the link between actual production and planning.
Easily replicate ZentONE on other machines to gain a fully digital view of your plant's production.
Install a ZentONE system with ZentOPS on each machine.
Add new ZentNode adapters to digitize specific signals such as temperature, pressure, consumption, or vibration.
Compare the efficiency of different lines and machines.
A single data model for all the factory allows the use of advanced AI models to optimize plant-wide production.
Comprehensive monitoring of a workstation comprised of two long-lived mechanical packaging machines (over 20 years old) and a modern PLC-controlled case erector.
The Challenge
Obtain accurate OEE metrics on machines of different technological generations, monitor the real-time consumption of critical raw materials (aluminum, cases, and boxes), and synchronize production with the corporate ERP system.
ZentONE Solution
Implementation of a ZentEdge microserver with eight ZentNode adapters interconnected via a Single Pair Ethernet network. External sensors were installed on the older machines to detect product flow, while the case erector was directly monitored using existing electrical signals.
A user-developed application sends production orders from the ERP to the operators and collects the OEE data recorded by ZentONE.
Investment
€9,900 (System configured + 2 days of specialized technical support for commissioning).
A modern packaging line with machinery from four different suppliers where actual throughput was significantly lower than theoretically expected.
The Challenge
To unify the overall line view without incurring the exorbitant costs of traditional SCADA-based solutions or compromising PLC security through uncontrolled external access.
ZentONE Solution
Each electrical cabinet was equipped with a ZentNode system that non-intrusively captures part flow signals. The ZentEdge system at the end of the line acts as a concentrator, generating large-format dashboards for the plant. This architecture ensures complete physical separation between the control (OT) and management (IT) networks, protecting assets against cyberattacks.
Results
Commissioning in just 2 days and a 19% reduction in downtime after only two months of data analysis.
Critical filling and labeling station with a production capacity of 45,000 bottles/hour, operating in intensive 24/6 cycles with 30-year-old PLCs lacking official support.
The Challenge
Accurately measure OEE without interfering with the control logic of obsolete PLCs and export the data to the plant's central SCADA system using standard industry protocols.
ZentONE Solution
Installation of a ZentEdge microserver with a ZentNode OEE adapter connected to photoelectric cells that detect the entry of filled bottles and the exit of conforming products after quality control.
Integration with the plant's SCADA system was achieved using Modbus/TCP, allowing a constant data flow to the production office without compromising the stability of the legacy machinery.
Deployment in a high-precision plant to monitor CNC lathes, milling machines, and plastic injection molding machines from various manufacturers.
The Challenge
Visualize the performance of each machine in real time, digitize batch selection to eliminate human error, and centralize historical data for continuous improvement analysis.
ZentONE Solution
A modular system was installed per machine, consisting of a ZentEdge and a ZentNode OEE adapter. The solution includes an intuitive HTML operator panel with support for peripherals (barcode scanner and keyboards). The system captures critical "On Cycle" and "Alarm" signals directly from the electrical panel, integrating production data into each server's local SQL database.
Investment
€3,900 per machine (System configured and ready for quick installation by the client).
Automatic real-time OEE
Detects stoppages, micro-stops, format changes, and speed losses without manual intervention.
Complete traceability
Records analog signals (consumption, sealing pressure, fill level, torque, flow rate, etc.) to guarantee quality, prevent defects, and maintain full traceability of each batch or unit produced.
Compatible with any packaging line
Installs in minutes without modifying controls or stopping production, with easy ERP integration.
Automatic real-time OEE
Detects stoppages, mold changeover times, micro-stops, and cycle losses without manual intervention.
Quality Asurance
Monitors mold pressure before each cycle to prevent defects and maintain complete traceability of every cycle and part produced.
Compatible with any injection molding machine
Installs on older or newer machines without modifying the original control system, with easy ERP integration.
Automatic real-time OEE
Detects tool waits, micro-stops, and speed losses without manual intervention.
Key parameter logging
records analog signals (spindle speed, load, hydraulic pressure, etc.) to ensure quality and prevent defects or breakages.
Compatible with any CNC
Installable on older or newer machines without modifying the original CNC, with easy ERP integration.
ZentONE is easy to install and maintain
No PLC programming
No machine modification
Zero network configuration
ZentONE provides an isolated and encrypted data path between your machines and information systems
Your machines are fully protected against any cyberattack to your IT system
The use of standard protocolos ensures compatibility with your existing infrastructure
ZentONE can be applied to any type of machine, regardless of its age, model or level of automation
The ZentEdge microserver is a robust device designed to operate in industrial environments. Its compact and impact and vibration resistant design makes it ideal for use in factories or warehouses.
ZentEdge includes all the necessary services to operate autonomously, without depending on the internet. It has database and application servers that allow the collection and processing of data in real time, guaranteeing the privacy and security of the information.
A lightweight and efficient link between real-time production data captured by ZentONE and the company's ERP system eliminates the need for a traditional MES system, enabling direct, secure, and bidirectional integration without complex intermediary layers.
With ZentOPS, production orders sent from the ERP can be automatically synchronized, allowing operators to select and manage active orders at the digital workstation. ZentOPS also records actual machine performance (OEE, production quantities, downtime, etc.) and returns this information to the planning system to maintain complete traceability and enable data-driven decisions that are updated instantly.
ZentNode simplifies access to machine data by directly connecting sensor signals and sending processed data via MQTT to information systems.
without programming PLCs
without configuring automation networks or communication drivers
no risks of cyber attacks
ZentNodeOEE
Masure the operating efficiency of any machine from only 2 signals
ZentNodeCT
High-Speed Counter (3Khz) for precise machine action
ZentNodeMT
Water, Energy and Material metering from pulse counters
ZentNodeEM
Measure electrical consumption with low-cost 4-20 mA power transformers
ZentNodeAL/C
Monitoring of 0-10V (AL) or 4-20mA (ALC) analog signals such as level, pressure or temperature
ZentNodeVM
Monitoring of machine vibrations according to ISO-10816 standard, using vibration sensors with 4-20 mA output.
ZentNodeIO
I/O Adapter with two 24VDC channels configurable as Input or Output independently
ZentNode
Modbus
Integrate Modbus RTU devices into ZentONE
Based on the Single Pair Ethernet technology of Perinet GmbH, ZentNet allows topologies that are easily adapted to the needs of any application
ZentNet is designed to be used in demanding industrial environments. Its components have IP67 protection and can work in a temperature range from -25ºC to 75ºC
By combining data and power in a single cable, ZentNet simplifies the connection to sensors distributed in the field
ZentinelMDS can advise you on how to automatically connect the data from your machines to your information systems.
With just one teleconference, we can prepare a machine digitization proposal tailored to your needs and budget.
ZentinelMDS offers training and support services tailored to your needs, including:
Training courses for your technicians
System Configuration
Single Pair Ethernet Network Design
Installation and commissioning assistance
ZentinelMDS provides systems tailored to the specific needs of users, including:
Custom ZentONE application development (operator screens, data logic...)
ZentOPS configuration for communication with ERP systems
DFactory
Calle 27, nº 10-16, Zona Franca
08040 | Barcelona | España
ACATE
Rodovia SC 401, nº 4120 | Sala 3
Saco Grande | Florianópolis | SC
CEP 88032-005 | Brasil
Send an email to ZentONE@ZentinelMDS.com for a ZentONE on-line demonstation