One Location Layer
Staff, forklifts, pallets and equipment all become visible over the same BLE network; the identity layer is never split.
06 · Industrial Automation
Industrial automation solutions
Automation solutions that bring positioning, safety and full control to vehicles, plants and open sites.
We understand the operational needs of different sectors in depth and build pioneering automation technologies in our own R&D center. What we offer includes BLE RTLS and AoA based real-time location infrastructure, the CreaAI in-house artificial intelligence layer that runs on top of all that data, mixer drum automation systems, geofence-based camera management, event-based recording systems and platforms for central data collection from factory machines, OEE and predictive maintenance.
- BLE RTLS
- AoA
- CreaAI
- Vector Index
- Excel Report
- Forklift Safety
- CCTV + AI
- Drum Automation
- Geofence
- Camera Management
- Event-Based Recording
- PLC / SCADA / CNC
- OPC UA & Modbus
- OEE & Downtime Analysis
- Predictive Maintenance
01 BLE PLATFORM
The factory's shared
The factory's shared
location layer
Integrated real-time location infrastructure for plants, warehouses, staff, forklifts, pallets and shuttle vehicles. One infrastructure, many uses, a scalable architecture.
BLE RTLS (Real-Time Location System) locates staff, vehicles, equipment and assets indoors in real time. Broadcasts from BLE cards and tags are picked up by Gateway or Locator devices in the field and turned into position data by the central RTLS engine.
RTLS is not a single staff-tracking application; it is a digital infrastructure on which different assets become visible over one network. Forklift safety, pallet and equipment tracking, warehouse counting, shuttle vehicles and CCTV/AI verification are all added on top of the same location and identity layer.
RSSI + AoA
Economical zone detection in ordinary areas, and precise X-Y positioning with AoA in critical areas such as forklift lanes and production floors.
CCTV + AI Verification
If there is no matching card signal in the zone where the camera detects a person, the system can treat it as a “person without a card” event.
02 CREAAI
In-house AI
In-house AI
that talks to your platform data
CreaAI is an in-house artificial intelligence layer that runs inside the platform. Live data from the field is indexed as vectors and interpreted together with a language model; the question asked is answered within seconds, and the same result turns into an Excel report.
BLE location data, drum status, geofence breaches, event records and production data collected from factory machines all accumulate on the same platform. CreaAI sits on top of that: instead of raising a report request, building a filter or hunting for the right screen, you ask the question in your own words.
The model is hosted on the infrastructure the platform runs on. Questions and records are never sent to a third-party AI service; the answer is built from the organization's own data, and the records it came from are listed.
Vector Index
Records are turned into embedding vectors; search runs on meaning rather than keywords, and the index is refreshed as data is created.
Answers in Plain Language
You write the question in everyday language; the answer arrives as text, a table and a short comment, and follow-up questions keep the context.
Excel, CSV and PDF
The answer on screen turns into a shareable file in a single step, and the same question can be made into a recurring report.
CRITICAL CHALLENGES
The critical challenges
The critical challenges
the sector faces
Scattered data sources, legal compliance obligations and a lack of machine visibility all hit production directly.
Scattered, Untrackable Processes
When data from different equipment and vehicles cannot be gathered in one place, operational visibility is severely limited.
Site Safety and Compliance
Balancing legal obligations — such as no camera recording in restricted zones — against site safety is getting harder.
Missed Incidents
Not being able to reach camera footage in time at critical moments makes incidents hard to analyze and act on.
No Visibility Into Factory Machines
Not being able to pull data from robot and machine controllers makes bottlenecks in production impossible to find.
03 DRUM AUTOMATION
Mixer drum automation: full control of mix quality
Our automation solution, developed specifically for the concrete and cement sector, detects in real time whether the mixer drum is turning, in which direction and at what speed.
Recording this data continuously provides both quality assurance and operational transparency.
Live Monitoring
Sensor technology tracks the drum's rotation direction, speed and status continuously.
Automatic Recording
Mixing data is logged with a timestamp, documenting the whole process.
Pour Alarm
If a vehicle starts discharging outside its assigned site, the system raises an alarm immediately.
04 GEOFENCE
Smart pour control with geofencing
Our system analyses the rotation direction of the mixer drum continuously to detect the moment of discharge automatically. The algorithm reads drum movement in real time and establishes, from position data, which geographic zone the concrete was poured in.
If a pour takes place outside the operating zones defined in advance, the system steps in immediately: it raises an audible and visual alarm and notifies the control center automatically. The speed at which the product was mixed on its way to the site is also logged.
Discharge Moment Detection
Continuous analysis of drum rotation direction establishes the moment discharge starts automatically.
Position-Based Verification
Which geographic zone the concrete was poured in is confirmed from position data and recorded.
Mixing Speed Log
The speed at which the product was mixed on its way to the site is logged.
Out-of-Zone Alarm
Pour attempts outside the defined zone raise an audible and visual alarm and notify the center automatically.
05 CAMERA MANAGEMENT
Automatic camera shutdown in restricted zones
At some facilities camera recording is prohibited by law for operational reasons. With Createch's geofence-based camera management system those facilities are marked once on a digital map. The moment a vehicle crosses into the defined facility boundary the cameras switch off automatically, and they come back on when it leaves the site.
This arrangement both guarantees legal compliance and keeps the entire safety record outside the facility unbroken. No manual intervention by operators is needed, the risk of error drops to zero, and legal obligations are managed systematically.
Zone Definition
Restricted facilities are marked once on the map, and the system remembers those boundaries permanently.
Automatic Activation
Cameras switch off as the vehicle crosses the boundary and back on as it leaves — no driver action needed.
Full Audit Trail
Logging when and where the camera switched off and on produces a compliance record.
Central Management
Zone rules for every vehicle are updated from one platform and monitored in real time.
06 EVENT-BASED RECORDING
Event-based camera recording
When a defined event occurs, recording is triggered automatically, and the footage from before and after is merged into a single file and sent to the people concerned.
Event Moment Detection
When an event defined on the system occurs, the camera system is triggered immediately and recording begins.
Merging Before-and-After Footage
Footage from before and after the moment of the event is merged automatically and archived as a single file.
Instant Delivery to the Right People
The merged event footage reaches the people concerned immediately, enabling strong remote analysis and fast decisions.
07 FACTORY INTEGRATION
Every machine
Every machine
in one place
Robots, CNC machines, presses, injection moulding machines and energy analysers meet in the same data model, whatever their brand or age. One platform, one time axis, comparable indicators.
We pull data directly from the controllers of factory robots, CNC machines and production equipment (PLC, SCADA, CNC) and bring it together on one central platform. The connection is made either through the controller’s own interface or over standard industrial protocols; the running machine program is never touched.
Older machines with no controller, or with no way of exporting data, are not left out of scope. On those machines a retrofit reading point is built with a current transformer, a proximity sensor or digital signal relays, so that at minimum the “running / stopped / cycle completed” state reaches the same platform.
That makes live status, performance and fault information for every piece of production equipment visible on one screen, and predictive maintenance data keeps unplanned downtime to a minimum.
The collected data is not only used for live monitoring. Because every record is stored with a timestamp, it can be compared retrospectively by shift, line, machine and product; the same data feeds the CreaAI layer, where it can be queried and reported in natural language.
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01 · SOURCE
Controller & Sensor
PLCs, CNCs, robot controllers, energy analysers and retrofit sensors.
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02 · COLLECTION
Edge Collector
An industrial computer on site connects to the sources read-only and buffers the data.
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03 · MODEL
Common Data Model
Tags from different brands map to one dictionary and a line, station and machine hierarchy.
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04 · OUTPUT
Dashboard, Alarm, Report
Live dashboards, rule-based alarms and periodic reports all come from the same data.
| Source | Protocol / Interface | Data collected | Typical interval |
|---|---|---|---|
| Siemens PLC | S7comm, Profinet, OPC UA | Machine state, counters, alarm bits | 1 s |
| Rockwell / Allen-Bradley | EtherNet/IP (CIP) | Tag-based state, production counters | 1 s |
| Other PLCs and drives | Modbus TCP / RTU | Register-based state, speed, current | 1–5 s |
| Standard server | OPC UA client | Tag tree, history, alarms and events | 1 s |
| CNC machine tool | FANUC FOCAS, Siemens 840D, Heidenhain | Program name, cycle state, spindle load, override | 1 s |
| Machine tool standard | MTConnect (HTTP / XML) | Availability, execution state, part counter | 1 s |
| Industrial robot | Vendor interfaces (ABB, KUKA, FANUC) | Mode, cycle time, program, fault code | 1 s |
| Energy analyser / meter | Modbus TCP, M-Bus | Active power, consumption, power factor | 5–15 s |
| Legacy machine, no controller | Digital I/O, current transformer, retrofit sensor | Running / stopped, cycle pulse | 1 s |
Read-Only Connection
The collector connects to the controller with read permission only. Nothing is written to the PLC program, the recipes or the machine settings; production flow is unaffected by the integration.
Local Buffer on Outage
When the network or the server becomes unreachable, records are held on the collector at the edge and transferred in order once the link returns. No gaps appear in the downtime record.
OT / IT Separation
The plant network stays in its own segment, the data flow is one-way outbound, and no door into the machine network is opened from the internet.
WHY COLLECTING DATA IS NOT ENOUGH
Every vendor stores the same fact under a different name: on one controller the running state is a single bit inside a data block, on another it is a text-based “execution” field. Unless those tags are translated into a common dictionary, what you end up with is not a comparable indicator but a pile of data scattered brand by brand.
That is why the first step of an integration is modelling rather than connectivity: a line–station–machine hierarchy and a state and downtime dictionary are defined first. Once the model is in place, “how long did the second shift stand still yesterday” means the same thing for every machine.
WHAT THE PLATFORM COLLECTS
- Machine state: Running, idle, setup, stopped and fault states, each recorded with a timestamp.
- Cycle and production counters: Part count, cycle time and deviation from the target cycle.
- Program and product data: CNC program name, work order and product code matched to machine state.
- Alarms and fault codes: The fault code raised by the controller, its description and its start and end times.
- Process values: Spindle load, feed rate, temperature, pressure, current and other analogue readings.
- Energy consumption: Active power and consumption per machine, separating out the energy burned while stopped.
COMMISSIONING
Start with one machine,
Start with one machine,
scale across the line
An integration does not have to begin as a project covering the whole factory at once. Once the setup is proven on a pilot line or a handful of critical machines, the same model is copied to the rest.
Production is not halted for the installation; connections are completed during planned maintenance windows or between shifts.
Site Survey and Tag List
The machine inventory is drawn up and the brand, model, protocol and network status of every controller is established. Which tag feeds which indicator is written down before any code is deployed.
Edge Setup and Connection
The collector is positioned on site and its network segment and access rights are defined. Retrofit reading points are installed on machines that have no controller.
Verification and Go-Live
Collected data is checked against the real counters and production records on the shop floor. Once the discrepancy is closed, dashboards and alarm rules go live.
14:12
The cycle signal on the press line drops; a downtime record opens automatically.
14:14
The operator enters the reason code from the shop-floor terminal: die change.
14:31
Production restarts; the stop is closed at 19 minutes and written into the shift report.
OEE AND DOWNTIME ANALYSIS
Not just how long a machine
Not just how long a machine
stood still, but why
Machine data on its own does not produce an indicator. Once stops are classified by cause, availability, performance and quality losses become visible separately.
The platform opens the downtime record automatically from the controller signal; the operator only picks the reason on the shop-floor terminal. The downtime log stops depending on what someone remembers at the end of a shift and becomes real-time and complete.
Reason codes are defined in the factory’s own vocabulary: die change, waiting for material, setup, maintenance, breakdown, missing operator. Because the same code set is used across all lines, losses can be compared by line and by shift.
Availability
How much of the planned production time the machine actually ran. Because stops carry a reason code, the source of the loss is visible directly.
Performance
Actual cycle time against target cycle time. Slowdowns and micro stops lasting only seconds are recorded one by one.
Quality
Scrap and rework rates for the parts produced. When quality records are matched with machine data, it becomes traceable which machine and which program the problem came from.
Classified Downtime
Every stop is tied to a cause. Instead of a total downtime figure, the report answers “what stopped us most this month” directly.
The Losses Nobody Logs
Short pauses that operators never write down are captured at signal level. Seconds that look insignificant on their own add up to a serious loss across a shift.
By Shift and by Machine
How long does the same product take on the same machine across different shifts? The same comparison can be made by line, by product and by team.
The Slow Link in the Line
Waiting and running times for every station on the line are placed side by side; the station that caps capacity is identified from data rather than guesswork.
PREDICTIVE MAINTENANCE
Data that warns you
Data that warns you
before the breakdown
Tying maintenance to a machine’s real workload rather than to the calendar reduces both unplanned downtime and the cost of servicing equipment earlier than it needs.
Because operating hours, cycle counts and load data accumulate continuously, a maintenance interval can be defined as “after this many cycles or this many operating hours” instead of “every six months”. A heavily used machine is serviced sooner, a lightly used one later.
Predictive maintenance is not a magic box: a meaningful trend analysis needs the machine’s normal operating range to have been recorded over a reasonable period. Projects therefore start with data collection and threshold-based alarms, and trend models are introduced as the history builds up.
Counter-Based Maintenance
Operating hours and cycle counters are tied to the maintenance plan; a work order is raised in advance for equipment approaching its threshold.
Threshold and Trend Alarms
An alarm is raised not only when a reading crosses a limit, but also when it drifts slowly away from its normal range. Gradual degradation is caught early.
Maintenance Window Planning
The warning is assessed together with the production plan, so the intervention lands in the window where the line was going to stop anyway.
INDICATORS WATCHED FOR EARLY WARNING
- Spindle and motor load: Load rising over time on the same program points to tool wear or a bearing problem.
- Servo current: Increasing current draw on axis movement shows that mechanical resistance is building up.
- Temperature and vibration: Measured with additional sensors and evaluated on the same time axis as machine state.
- Hydraulic and pneumatic pressure: A gradual drop in pressure is the first sign of a leak or a worn seal.
- Cycle time drift: A cycle that quietly gets longer usually shows up well before a visible failure does.
- Repeat rate of fault codes: Minor faults that operators reset and move past become more frequent ahead of a major breakdown.
08 RESULTS
Measurable operational benefits
The concrete gains factory automation integration delivers in production processes.
Machine Visibility
The status of every robot and machine in the plant is monitored live from one platform.
Faster Fault Detection
A central data flow means faults are found faster and response time is shorter.
Less Downtime
Predictive maintenance data keeps unplanned downtime to a minimum.
Data Availability
Data integration from machines of different brands and protocols is handled in one structure.
09 WHY CREATECH
Why choose Createch
Why choose Createch
solutions?
Home-grown engineering strength, sector experience and a way of working focused on measurable results.
Home-Grown R&D
Through our in-house R&D center we develop innovative, sustainable solutions built for the needs of industry.
Sector Expertise
Many years of experience in the sector mean we know the operational needs of sector leaders at first hand.
Continuous Support
Our expert technical team provides fast, effective service to keep your operations running.
Measurable Results
The solutions are designed to deliver concrete efficiency gains and cost savings in operational processes.
10 CONTACT
Take your operations into the future
Digitize your processes, monitor your machines and take full control of the field with Createch's industrial automation solutions. From mixer drum automation to factory machine integration, and from geofence-based camera management to event-based recording, we put together solution packages for your specific needs.
Get in touch for detailed information, project consultancy and demo requests. Our technical team is ready to put together an automation solution for you.