Ask your machine what happened.
PLC Monitor is an AI tool on a box in your plant. It reads your Allen-Bradley Logix controller, warns you when something starts to drift, and tells you in plain English why the line stopped.
NewLong Conversations upgrade: talk through weeks of history with your machine →One fault, start to finish
A clamp starts slowing down. Follow it from the first warning to the fix.
Simulated demo. Example machine and data.
Line 3, case clamp stationRunning
Clamp 2 extend time, msNormal
The rung behind the fault
PLC Monitortype it or say it
What the demo shows: PLC Monitor reads a Logix controller on a clamp station. The clamp's extend time climbs out of its normal band and the monitor sends an early warning. The clamp then times out and the line stops. The monitor names the rung and the prox sensor, PX-214, that never turned on. A technician asks what happened and gets a plain-English answer, leaves a voice note about the fix, and later resets the baseline after a new cylinder is installed.
Line 3, first-hour cycle time, secondsMondays slow
What it read to answer
- 6 weeks of Line 3 cycle data
- Shift schedule and start-up times
- Glue pot temperature tag
- Fault history and 3 voice notes from maintenance
- Line 3 PLC program, GluePot routine
PLC Monitor, Long ConversationsQuestion 1, remembers all 1
What the demo shows: a plant manager asks why Line 3 is slow every Monday morning. The monitor looks across six weeks of cycle data and finds the first hour on Mondays runs about 14% slower because the glue pot takes 38 minutes to heat up after the weekend. A follow-up shows second shift is not affected. It recalls a maintenance voice note from March about the heater relay, suggests a pre-heat timer and a heater band check without changing the PLC, and writes a summary for the maintenance meeting.
Long conversations come with the Long Conversations upgrade: a larger AI model on a more powerful computer in your plant.
Less time hunting, more time running
Most downtime is not the repair. It is finding out what to repair.
Warns you before the fault
It learns what normal looks like for each machine: cycle times, pressures, currents, counts. When something drifts out of that band, you hear about it while the line is still running.
Points at the exact cause
When a machine stops, it traces the fault back through the logic to the rung and the device that tripped it, and says so by name.
Answers in plain English
Ask "what happened on Line 3?" or "why won't the clamp extend?" and get an answer a second-shift tech can act on without opening the program.
Listens when you talk back
Tell it what the fix really was, by typing or by voice. That note stays with the fault, so the next person sees what worked last time.
Resets when the machine changes
New cylinder, new recipe, new speed? Tell it to reset a baseline and it starts learning the new normal instead of nagging about the old one.
Stays in its lane
It reads the PLC and never writes to it. Your machine data and conversations stay on the box in your plant on every level.
From walkthrough to first warning
Walk the machine
We look at the controller, the network, and the faults that cost you the most time.
Install the box
One small box in or near the panel, connected to the PLC. No program changes.
Let it learn normal
It watches the machine run and builds a baseline for the signals that matter.
Start asking
Your team gets warnings and answers. We tune it with you on real faults.
One monitor, three ways to connect it
Every level does the same job: early warnings, the cause named, plain-English answers, voice notes and baseline resets. Every level includes an operator station at the machine and a web page any computer on your plant network can open. Your machine data and conversations stay in your plant. The difference is how alerts reach your people and how we keep watch on the box itself.
Local
For plants where nothing leaves the building.
- Box on site, read-only to the PLC
- Operator station at the machine: touchscreen, sealed keyboard and a push-to-talk mic built for a noisy floor
- A web page any computer on your plant network can open
- No outside connection at all
Higher one-time price, no monthly fee.
Call for a quoteConnected
For maintenance teams that are not always at the machine.
Everything in Local, plus
- Alerts and reports by text or email, sent to your people through your plant’s own email or text system
- We watch the box’s health (running, no crashes, no errors) and keep its software up to date
- Uses your plant’s internet connection
Monthly price.
Call for a quoteCellular
For remote sites, or plants that keep vendors off the network.
Everything in Connected, plus
- Its own cellular connection, used for the box’s health and simple usage counts, never what was asked
- If you choose, text summaries to your team’s phones over the same cell line
- Never touches your plant or office network
- Works at pump stations and unmanned sites
Lower upfront, with a monthly fee for cellular service.
Pilots run on Cellular.
Request a pilotWant longer conversations? Add the Long Conversations upgrade to any level. A larger AI model on a more powerful computer in your plant lets your team talk through weeks of history, ask follow-ups and build a plan with the machine.
See Long ConversationsWhat it works with today
PLC Monitor works with Allen-Bradley / Rockwell Logix controllers today. That covers most of the ControlLogix and CompactLogix machines on plant floors in this region.
We program GE, FANUC, Mitsubishi and Omron too, and the monitor can be extended to other platforms. If yours is not Logix, call us. It helps us decide what comes next.
Why a controls shop built this
We get the 2 a.m. call when a line is down. Most of that call is spent finding the one sensor or one rung that matters. This tool does that part first.
Need the logic fixed too?
When the monitor keeps pointing at the same weak spot, we can fix the program, the panel, or the mechanics behind it. See PLC programming.
Common questions
Does it write to the PLC?
No. PLC Monitor only reads. It never writes a tag, forces an output, or changes your program.
Where does our data go?
Your machine data, fault details and conversations stay on the box in your plant on every level. You see them on the operator station at the machine, or on a web page any computer on your plant network can open. On Local, nothing leaves the building at all. On Connected, alerts and reports go to your own people through your plant’s email or text system, and the box sends us only its own health: that it is running, has not crashed or flagged an error, and is up to date. On Cellular, the box sends us that health plus simple usage counts, like how many questions were asked and answered, but never what was asked. If you choose, it can also text summaries to your team’s phones. All of that goes over its own cell connection, so it never touches your network.
Which PLCs does it work with?
Allen-Bradley / Rockwell Logix controllers today, such as ControlLogix and CompactLogix. If you run another platform, tell us which one. That is how we decide what to add next.
Do we have to change our PLC program?
No. It reads the tags and logic you already have. If a machine has no useful tags for a fault you care about, we will tell you what to add and can add it for you.
Will it stop every fault?
No, and nobody honest will promise that. It warns you when a machine starts drifting from normal, and when something does stop it points at the rung and the device that caused it.
What is a pilot?
We put a box on one machine or one line, let it learn what normal looks like, and you use it on real faults. Pilots run on the Cellular level so we can watch the box’s health and see high-level usage, like how often your team asks it something, without touching your network. What gets asked, and your machine data, stay on the box. During the pilot we can also log in remotely to adjust the box based on your feedback. That is spelled out in the pilot agreement, logged on the box, and ends when the pilot does. If your plant cannot allow any outside connection, ask us about a Local pilot. If it does not earn its spot, we take it back out.
Have a machine that keeps stopping?
Put a monitor on it. We are taking a small number of pilot sites now.