IIoT platform for mid-sized manufacturers
One platform for your entire production.
From the machine to plant management: MectoSYS collects data from all your machines and turns it into line status, downtime reasons and OEE, plus quality, workforce, audit and remote service in one interface – in the cloud or in your plant.
- 01
Your machines
Any make. They send only the data you release.
- 02
Data PLC and gateway
Provided by MectoSYS. Collect, buffer, transmit encrypted.
- 03
MectoSYS platform
Line status, downtime, OEE, quality, workforce and audit.
- 04
Your team
In the browser: shift leads, maintenance, plant management, service.
The situation
In many plants, downtime only becomes visible once the shift is over.
- 01
Data stays in the controller
Cycle times, part counts and fault codes exist in the PLC. Nobody outside the machine can see them.
- 02
Short stops vanish in the shift report
Recurring faults and waiting times are estimated afterwards instead of measured. Root causes stay unclear.
- 03
MES suites do not fit mid-sized plants
High licence costs and long integration projects are out of proportion for a 50-person plant.
How it works
From the signal in the controller to the KPI in the browser.
A MectoSYS data PLC is the common collection point for all machines. Each machine writes the data you release to a fixed address. A gateway transmits it, encrypted, to the MectoSYS platform, where signals become machine states and KPIs.
- Step 1
Create a tag
You create a tag in MectoSYS. The platform assigns it an address in the data PLC.
- Step 2
Send
Your machine writes the value to that address: Siemens via PUT, other makes e.g. via Modbus TCP.
- Step 3
Transmit
The data PLC provides the values via OPC UA. The gateway transmits them via MQTT over mTLS and buffers if the network fails.
- Step 4
Analyse
States such as Running, Setup or Fault, downtime with reasons and OEE for shift leads, maintenance and plant management.
Operating models
Your data stays where you decide.
MectoSYS is available as a cloud service and for operation inside your own network. Features and operation are identical.
| Aspect | MectoSYS Cloud | MectoSYS On-Premise |
|---|---|---|
| Data storage | Data centre in Frankfurt am Main (EU) | Server or virtual machine in your plant. Production data never leaves your network. |
| External connection | Outbound only, MQTT over mTLS | Not required |
| Operation and updates | Fully handled by MectoSYS | Software and updates from MectoSYS, running on your infrastructure |
| Remote maintenance | Included | Only with your approval |
| Best for | A fast start without your own IT infrastructure | Strict data protection or customer requirements and isolated networks |
NIS2, the Cyber Resilience Act and the new Machinery Regulation make cybersecurity in production mandatory. With MectoSYS, nobody accesses your controllers from outside: your machines send only released data, encrypted and with device certificates.
- No access to your controllers
- Encrypted, with device certificates
- Audit log, roles and permissions
- EU hosting or on-premise
Platform
Line status, downtime and OEE in one interface.
- Line status
- All sites, areas, lines and machines in one tree view with live state.
- Downtime capture
- Every stop is detected automatically and assigned a reason.
- OEE
- Availability, performance and quality, calculated from time and shift models.
- Andon and alerts
- Faults visible immediately to everyone who needs to react.
Remote service worldwide
Live state, fault codes and history of every machine you shipped. Remote access with TIA Portal from your engineer’s laptop, without your program code ever leaving the machine.
Remote serviceTurnkey projects
Building complete lines for mid-sized plants? Deliver MectoSYS as the operating platform for production, quality, workforce and audit.
Turnkey projectsHardware
Developed and tested on real industrial hardware.
Our demonstrator uses the same components as many mid-sized plants: machine controller, data PLC, industrial Ethernet network and gateway. The platform receives real machine data from it.
| Pos. | Component |
|---|---|
| 1 | SIMATIC S7-1500Machine controller. Writes its released data into the data PLC via PUT. |
| 2 | SCALANCE XC208Industrial Ethernet switch. Separates OT and management networks via VLANs. |
| 3 | SCALANCE S615Firewall and VPN. Outbound connections only, remote access with TIA Portal after approval. |
| 4 | SIMATIC S7-1200MectoSYS data PLC. Collection point for the data of all machines, provides it via OPC UA. |
| 5 | SIMATIC IOT2050MectoSYS gateway. OPC UA client of the data PLC, local buffer, MQTT over mTLS. |
Economics
What does unmeasured downtime cost you?
A few minutes per machine and shift add up to significant costs over a year. Enter your own values.
Your assumptions
Result
Downtime cost per year
€130,333
| Downtime per year | 1,533 h |
|---|---|
| Equals shifts of the whole line | 24 |
| Value of 10 % less downtime | €13,033 / year |
Rough estimate based on your assumptions. Not a substitute for an on-site analysis.
Pilot programme
We are looking for pilot partners in manufacturing.
We bring MectoSYS to one of your lines, provide the data PLC and gateway and handle the setup together with you. You gain transparency over your line and help shape further development.
- 1First call30 minutes, online
- 2Site visitLine, controllers and network
- 3InstallationData PLC, gateway, signal mapping
- 4Pilot operationLive data, regular check-ins
- 5ReviewResults and next steps
Working together
MectoSYS grows with partners.
The founding team is being built. Besides pilot customers, we are looking for people and companies who will take MectoSYS to market with us.
Pilot customers
Manufacturers who use MectoSYS on one line and help shape its development.
Pilot programmeCo-founder
A co-founder for marketing and business development, ideally with experience in industry.
See the profileCompany partners
System integrators, machine builders and automation companies: as a technology partner or to integrate MectoSYS into your company.
PartnershipsCompany
Rooted in automation. Built for the Mittelstand.
MectoSYS is a startup project at HIKE Lab, the startup incubator of Nordhausen University of Applied Sciences. We combine control engineering and software and develop the platform together with manufacturers.
Get in touch
Ratikanta Mishra
Founder, MectoSYS
Would you like to test MectoSYS on your line?
We are looking for manufacturers for our pilot programme. In a first call (30 minutes, online) we check whether your plant is a fit.
Or give us a call: +49 1551 0940487