The role of data visibility in preventing industrial equipment failures and operational errors (part 2)
Date: 11/03/2025 | By: IDEC HQ
Loading...
Industrial equipment runs on more than power – machines and their operators need a reliable flow of data.
Without it, inefficient processes and uninformed actions can easily lead to equipment failures. The resulting downtime and loss of productivity can cost businesses time, money, and more.
In the first part of this series, we looked at the typical causes of equipment failures and operator errors, and the most common factors behind them.
In this article, find out more about:
The ultimate cause of industrial equipment failures
Data visibility to anticipate errors and transform work processes
IDEC safety devices that bring added data visibility to industrial systems
The ultimate cause of industrial equipment failure: a lack of accurate data
Every cause listed in part 1 has something in common: the amount of information available. Specifically, that the amount of information available isn’t enough to keep equipment in the best possible condition.
In manufacturing and other industrial applications, trends shaping new processes and their effectiveness are driven by real-time data. As such, the data that businesses hold must reflect their current situation as accurately as possible.
Industries with poor data visibility deal with varied problems:
They don’t collect enough data to gain a clear picture of their situation
They can’t collect enough data due to data silos and system incompatibility
They collect a lot of data but don’t trust the quality (inconsistency/bias)
They collect a lot of data but don’t know how to analyze/use it effectively
Thankfully, technological advancements (Industry 4.0 developments) continue to simplify data collection and analysis.
The Industrial Internet of Things (IIoT) has revolutionized system design, and the ways that connected devices can be used to enhance data sharing and analytics. Alongside IoT-enabled predictive maintenance, cloud computing gives workers the ability to view the latest information remotely.
Data visibility: the key to anticipating errors and transforming work processes
The most effective decision making is informed by a wealth of reliable data, and supported by tools for accessing, analyzing, and using that data:
Real-time status information: improve quality control and prevent failures.
High-quality displays: see outputs, trends and anomalies with greater clarity.
IIoT-connected devices: understand how efficiently and effectively devices work together in your system.
Portable interfaces and controls: respond to changes and make adjustments at any time, even remotely.
IDEC’s IIoT-enabled and safety-related devices help you bring added data visibility to industrial systems
Smart, connected devices in your system work to reduce the risk of industrial equipment failure. The IDEC product lineup makes real-time analytics in industrial automation systems easier to achieve.
FC6A MicroSmart Plus PLC: for web server functionality
The built-in web server provides two-way communication between the PLC and connected computers, tablets, etc. Remote users can view data on custom web pages, easy to create without HTML knowledge using the editing software.
The FC6A MicroSmart Plus can also connect to the cloud (AWS IoT Core/Azure IoT Hub) and on-premises servers via the MQTT and MQTT Sparkplug B protocols, act as an FTP client or server for data transfer, or send system update emails and texts via Ethernet.
SX8R bus coupler module: for remote I/O systems
Take advantage of the SX8R’s support Modbus TCP/IP and EtherNet/IP network protocols to enhance device communication and data sharing.
For preventive maintenance, some additional sensors are required to detect equipment failures. If sensors are added, wiring becomes more complex. The SX8R for remote I/O solves this wiring issue, as it can collect all sensor data via just one Ethernet cable.
HG series operator interfaces: for clarity and reporting
The slimline bezel on the HG1J and HG2J is designed to maximize the display size. Both screens grant literal high visibility, with high-resolution TFT color LCDs and a glass top surface.
The PCAP touchscreen’s tempered glass surface has advantages in industrial settings where displays are physically harder to see: UV resistance, scratch resistance, and easy cleaning.
Both units are made for full integration with IIoT-enabled systems, with MQTT cloud communication alongside FTP server/client and web server functions, network protocol support, Ethernet, USB, RS232C, RS422/485, and Wi-Fi (using a dongle).
FT series operator interfaces (PLC + HMI): for control and monitoring
The FT1J and FT2J are essentially HG1J and HG2J models with an additional PLC located behind the display. They feature dual CPUs—one dedicated to control functions and the other to HMI functions—to maintain high processing speeds.
With a PCAP touchscreen at the front, full IIoT capabilities internally, and a PLC with I/O points at the back, the FT series is an ideal control and monitoring solution for equipment or systems with space constraints.
Safety Commander series: for remote operation
The HT3P and HT4P securely hold industrial-use tablets of varying sizes. The attached tablet can be positioned horizontally or vertically, and operated comfortably by left-handed or right-handed users.
With a connected tablet in hand, workers don’t need to be standing in front of the control panel to view operational data and check work logs. It’s also possible to activate the machine’s emergency stop function while using a tablet, with the Safety Commander’s built-in emergency stop switch.
Use quality, highly visible real-time data to prevent industrial equipment failures and work smarter
IDEC’s reliable connected device range adds value in every area of an industrial control system. Discuss data visibility levels and IIoT solutions with your regional IDEC sales team.
We provide a wide range of help and resources:
If you have questions or suggestions, we're here to listen.
Our sales and support teams are on hand to help.
All the technical documentation you need.