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PLC Alarm Analytics — Machine Health & Preventive Maintenance

Fleet-wide view of PLC alarm history across installed systems. Built to answer three questions: which machine needs attention, which component is failing, and when will it fail again.

Data sources
Add alarm CSVs Drop *_Alarm_His_*.CSV files here, or click to choose

Fleet overview

Alarm behaviour over time

Alarm volume over time, by severity

Spikes mark process upsets or a component starting to fail. A rising Major band is the earliest fleet-level warning of a breakdown.

When alarms happen — day × hour

Concentration in one shift or one hour points at an operating practice or a start-up sequence, not a broken part.

Alarms by shift

Shift A 06–14, B 14–22, C 22–06. A skewed split is an operator-training or handover finding rather than a mechanical one.

Machine comparison

Observation windows differ per machine (from 9.6 h to 70 h in this sample), so raw alarm counts are not comparable across sites. Everything in this section is normalised to alarms per day.

Alarm rate by machine (per day)

The service-priority ranking. Highest bar = the site your engineer should visit first.

Machine health scorecard

One row per installed system. Sort by any column; click a row to filter the whole dashboard to that machine.

Root cause & preventive maintenance

Pareto — which alarm codes cause most of the noise

Codes above the 80 % line are the short list. Fixing them removes the bulk of all alarms.

Component hotspots

The unit number lives only in the alarm text (Diverter Valve-14, Silo-3), so it is parsed out here. This is the physical part to inspect.

Chattering alarms — nuisance vs. real

Share of each code's events that repeated within 60 s. A high share means a flapping sensor or a loose limit switch, not a genuine repeat failure.

Alarm chains — what follows what

Pairs seen within 10 minutes on the same machine. A consistent chain is the causal path from first symptom to trip.

Alarm code catalogue

Recurrence interval (MTBA) is the preventive-maintenance signal: a code with a short, stable MTBA is predictable and can be scheduled out. Click a row to drill in.

Process accuracy

Weighing deviation — set point vs. actual

Weight-variation alarms carry Set: and Act: values in the alarm text. Drift in one direction indicates load-cell calibration, not a jam.

Alarm log

Filtered alarm events

The underlying records behind every chart above, with the parsed fields added. Export applies the current filter.