Key takeaways
- A manufacturing production monitoring system records machine status, output, cycle times and downtime automatically, so the shift is measured instead of estimated.
- Systems differ most in how they get the data: from the PLC, from sensors, from cameras, or from operator input.
- Monitoring shows the loss. What matters next is who acts on it, and whether that happens in the same system.
- Each vendor description is based on the vendor's own website, checked in September 2026. The "Things to consider" notes are our own suggestions, and Fabrico is our product.
- Test any system on your bottleneck machine and compare its numbers with what you already know.
What is a production monitoring system?
A production monitoring system, also called production monitoring software or a manufacturing monitoring system, is hardware and software that tracks what manufacturing equipment is doing, in real time.
It replaces paper logs and end-of-shift estimates with a live timeline of every machine: running, stopped, in changeover, and how much it produced.
For the full background, read our guide to production monitoring systems in manufacturing.
What a production monitoring system measures
| Data | Why it matters |
|---|
| Machine state | Shows when the machine runs, idles or stops |
| Part counts | Shows output against target, good and rejected |
| Cycle time | Shows whether the machine runs at its ideal speed |
| Downtime and reasons | Shows where time is lost, and why |
| Short stops | Reveals losses that manual logs usually miss |
| OEE | Combines availability, performance and quality into one score |
The difference between production monitoring and OEE is explained in production monitoring vs OEE.
Four ways manufacturing monitoring systems get production data
| Data source | Strengths | Things to plan for |
|---|
| PLC or machine controller | Detailed and accurate, including alarms | Access to the controls and coordination with automation engineers |
| Retrofit sensors | Works on older machines, quick to install | Stop reasons often need operator input |
| Cameras | Covers steps with no electrical signal | Clear rules on what is filmed and who sees it |
| Operator input | Adds context, such as the reason for a stop | Depends on discipline, and often misses short stops |
Most plants end up combining sources. See PLC connectivity, monitoring without a PLC and cameras without surveillance.
7 production monitoring systems at a glance
We picked systems that monitor machines automatically and publish their capabilities on their own websites, checked on 16 September 2026.
Fabrico is listed first because it is our product. The other six are listed in alphabetical order, not ranked.
| System | Machine data and fit, per the vendor |
|---|
| Fabrico | Data: PLCs, IoT sensors and AI cameras
Best suited to: Plants that want OEE and a full CMMS in one platform |
| Epicor Advanced MES | Data: Machines and sensors, including Epicor's own data collection unit
Best suited to: Manufacturers in the industries Epicor lists, such as fabricated metals, industrial machinery and plastics |
| MachineMetrics | Data: CNC and PLC controls, Kepware and OPC UA, plus IO and sensor paths
Best suited to: Discrete manufacturers, including job shops and contract manufacturers |
| Plex Production Monitoring | Data: Machine connectivity through Plex MES A&O
Best suited to: Discrete, hybrid and regulated manufacturers |
| Redzone | Data: Automatic collection, with integrations to SCADA, PLCs and edge devices
Best suited to: Enterprise manufacturers that want production, quality and maintenance teams on one platform |
| Tulip | Data: Edge devices with OPC UA and Node-RED, feeding no-code apps
Best suited to: Manufacturers that want composable, configurable operator apps |
| Vorne XL | Data: A hardware appliance wired to line sensors, with a PLC data link
Best suited to: Discrete manufacturing processes |
1. Fabrico
Disclosure: Fabrico is our product.
What it is: an OEE platform with a full CMMS built in, so production losses and maintenance work live in the same system.
How it monitors production
- Machine data from PLCs, IoT sensors and AI cameras, including machines without a usable control signal.
- Real-time OEE dashboards with availability, performance and quality.
- Micro-stop detection, plus downtime, MTTR and MTBF analytics by machine.
- Push, in-app and email notifications with configurable rules.
- An AI assistant built into the platform.
- Connections to SAP PM and, through custom integrations, other ERP systems, plus a REST API and webhooks.
Maintenance
Because the CMMS is built in, your team can open a work order, add a task to a preventive maintenance plan and check spare parts stock from the same platform.
Technicians work from iOS and Android apps and can scan QR codes on machines.
Things to consider
- Fabrico does not offer production scheduling today; it is on the roadmap. Plan scheduling in your ERP or a dedicated tool.
- Machines without a usable signal need sensors or cameras first. Include that in your rollout plan.
2. Epicor Advanced MES
What it is: Epicor says Advanced MES "collects data directly from equipment and operators on the shop floor in real-time, maximizing data accuracy and process automation."
How it monitors production
- Automatic capture of data from machines and sensors, including Epicor's own Connected Factory Machine Interface Unit.
- Real-time visibility when a machine is not running efficiently.
- Automatic messaging and escalation to supervisors, maintenance crews and engineers.
- OEE improvement from automated production monitoring, with deeper OEE analytics in Epicor Data Analytics for Advanced MES.
Maintenance and other modules
- Epicor lists modules for SPC and SQC, scheduling and preventive maintenance.
Things to consider
- Epicor says Advanced MES connects with your existing ERP system. Confirm the connector for the ERP you run.
3. MachineMetrics
What it is: MachineMetrics calls its platform, MaximaOS, "the AI-powered operating system for discrete manufacturing."
How it monitors production
- Native connections to CNC and PLC controls, connections through Kepware and OPC UA, and IO and sensor paths for machines with no modern control.
- MachineMetrics says downtime events "are detected the moment they happen, straight from machine data, with no operator input and no minimum duration."
- Utilization, OEE, downtime and setup reports come out of the box.
- An AI interface lets users ask about production, downtime, OEE or cost in plain language.
Maintenance
- MachineMetrics says condition-based alerts trigger work orders in your CMMS. Confirm the connection to the CMMS your maintenance team uses.
Things to consider
- MachineMetrics says it runs cloud-delivered, with edge devices managed centrally across sites. Share its IT and security details with your IT team early.
4. Plex Production Monitoring (Rockwell Automation)
What it is: Plex says its Production Monitoring Software, "powered by Plex MES A&O, provides seamless connectivity to and from machines on the plant floor."
How it monitors production
- Machine status, output and downtime as it happens, according to Plex.
- Measurement of quality, OEE performance and availability.
- Part of the wider Plex Smart Manufacturing Platform, which also covers MES, quality and scheduling.
- Rockwell describes FactoryTalk ResilientEdge as an MES edge solution that extends cloud-based manufacturing execution to the edge.
Maintenance
- Plex markets preventive maintenance within its MES, and maintenance requests from Plex APM.
Things to consider
- Plex Production Monitoring is powered by Plex MES A&O and sits inside the wider Plex platform. Ask Plex which components a monitoring-only rollout needs.
5. Redzone
What it is: Redzone describes itself as "a connected workforce platform for manufacturers that helps production, quality, and maintenance teams work together in real time."
How it monitors production
- Redzone says it provides "live OEE tracking for every line, cell, and shift."
- Downtime and throughput are collected automatically and linked to the line, run and assets.
- Automatic Pareto charts show top losses by frequency and duration.
- Integrations cover plant floor technology such as SCADA systems, PLCs and edge devices, and it works on iOS and Android devices.
Maintenance
- Redzone describes its Reliability module as CMMS software, for maintenance work orders and PM programs.
Things to consider
- Redzone is organized into modules for productivity, reliability, scheduling, compliance and learning. Confirm which ones you need.
- Redzone says it is built for enterprise manufacturers operating across multiple sites and regions. Ask Redzone how a rollout would look for your number of sites.
6. Tulip
What it is: Tulip describes itself as a frontline operations platform, and says its composable platform gives "every site, team, and system a single place to build, connect, and improve."
How it monitors production
- Production tracking apps that collect data "from the people, machines, and sensors throughout your operations."
- OEE calculation and equipment status displays.
- Machine connections through Tulip's edge devices, including OPC UA and Node-RED.
- Operators can flag issues and down equipment, and alerts go to the right people.
Maintenance
- Tulip offers a CMMS App Suite in its Library for requesting, scheduling and executing maintenance work orders.
Things to consider
- Ask Tulip which Library apps fit your process as delivered and which you would configure.
7. Vorne XL
What it is: Vorne describes XL as "a standalone device that includes I/O to communicate with your process, a scoreboard for your operators, and built-in reporting for your managers."
How it monitors production
- Vorne says XL "captures data directly from sensors on your line for automated counts, cycles, and downtime detection."
- Sensor inputs can come from an existing photo-eye, relay, proximity switch or encoder, and a PLC data link is available.
- Built-in reports include OEE, downtime, TEEP, changeover and top losses.
- Downtime reasons are captured at the line, and the optional XL Enterprise cloud component adds features such as email and text alerts.
Things to consider
- XL is a hardware appliance that runs inside your firewall, with no cloud requirement. Plan how many devices you need, since Vorne says XL scales from one machine to an entire enterprise.
- Vorne says XL works on any discrete manufacturing process. Pick the sensor signal that will count parts on each line before the pilot.
How to choose production monitoring software
- Start from your machines. List which ones have usable PLC data, which need sensors, and which need cameras.
- Ask how short stops are captured. They are often the biggest hidden loss, as our micro stops guide explains.
- Check the OEE math. Ask each vendor to calculate one of your shifts with the standard OEE formula.
- Test the operator screen at the line, including how stop reasons are entered. Our guide to reason code design helps here.
- Decide what happens after a stop: who is alerted, and where the follow-up work is managed.
- Check integrations with your ERP and the data export you need.
- Review hosting and security, including certifications and where the data is stored.
- Agree a pilot with clear success criteria before a wider rollout.
Match the system to the problem
| If your main problem is | Look first at |
|---|
| Losses turning into repeat breakdowns | A system with maintenance work built in or tightly integrated |
| Operators not seeing the target during the shift | A system with a strong line-side scoreboard |
| Many CNC machines from different builders | A system with native CNC connectivity |
| Many sites to standardize | A system built for enterprise, multi-site rollouts |
| Unique workflows at each station | A configurable app platform |
What good looks like after 90 days
- The bottleneck has a trusted OEE baseline, and nobody argues about the numbers.
- Every stop longer than your threshold has a reason.
- The team has fixed at least two or three top losses, and can show the minutes won back.
For the fixes themselves, see how to reduce machine downtime and how to improve OEE.
See how Fabrico works
If you want monitoring and a full CMMS in one place, Fabrico shows your losses in real time, and your team can open work orders for them in the same platform.
Book a demo. For six more real-time tools, see our real-time production monitoring software comparison.
For a wider view of floor software, see our guide to the best shop floor management software.
Sources: each vendor's public website, checked on 16 September 2026. Product names are trademarks of their owners.
Features change often, so confirm details with each vendor.
Frequently asked questions
What is production monitoring?
Production monitoring is the real-time tracking of machine and line performance: status, output, cycle times, downtime and OEE.
It usually relies on data from PLCs, sensors or cameras, with operators adding context.
What is the difference between a production monitoring system and MES?
A production monitoring system focuses on what machines are doing and how much they produce.
An MES is usually broader and can also cover scheduling, quality, traceability and work instructions.
Is production tracking software the same as a production monitoring system?
They overlap. Production tracking software records output and job progress, often with operator input.
A production monitoring system also collects machine data automatically.
Can production monitoring work on old machines?
Yes. Retrofit sensors can detect running, stopped and cycle signals on most machines.
Cameras can cover steps that have no electrical signal at all.
How long does it take to set up production monitoring?
It depends on the number of machines, the data source and your IT requirements.
A pilot on one machine or line is the fastest way to find out, and it should come with agreed success criteria.
How much does a production monitoring system cost?
Vendors price in different ways, for example per machine, per site or per user, and some include hardware.
Ask each vendor to quote the same scope so you can compare fairly.
Does production monitoring improve OEE by itself?
No. It makes losses visible, which is the first step.
OEE improves when the team fixes the biggest losses and turns each fix into a standard.
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