Skip to content
Open
Show file tree
Hide file tree
Changes from all commits
Commits
File filter

Filter by extension

Filter by extension

Conversations
Failed to load comments.
Loading
Jump to
Jump to file
Failed to load files.
Loading
Diff view
Diff view
2 changes: 2 additions & 0 deletions src/blog/2026/07/control-and-track-factory-floor-machines.md
Original file line number Diff line number Diff line change
Expand Up @@ -3,6 +3,8 @@ title: "Control and Track Machines on the Factory Floor"
subtitle: "Build a FlowFuse dashboard to control a PLC-connected motor and stack light, then track runtime automatically"
description: "Learn how to connect FlowFuse to a Siemens S7 PLC, build an operator dashboard to control a motor and stack light, and automatically track device runtime using the Hourglass node."
date: 2026-07-02
usecase:
- shop-floor-communication
authors: ["sumit-shinde"]
image: /blog/2026/07/images/control-and-monitor-machines.png
tags:
Expand Down
99 changes: 99 additions & 0 deletions src/use-cases/shop-floor-communication.njk
Original file line number Diff line number Diff line change
@@ -0,0 +1,99 @@
---
title: "Shop Floor Communication"
meta:
title: "Shop Floor Communication | Use Cases | FlowFuse"
description: "Andon, alerts and escalations that reach the right people in seconds: from machine events to team channels, displays and phones. Built on Node-RED, managed with FlowFuse."
problem: "The line stopped four minutes ago. The person who can fix it will find out when someone walks over."
industries: ["automotive", "food-beverage", "aviation-aerospace", "electronics-appliances"]
values: ["labor-operational-efficiency"]
architecture: "edge-connectivity"

customerPain:
heading: "Events travel at walking speed."
intro:
- "Machines know the moment something needs attention. Getting that moment to a human still relies on stack lights someone must see, radios someone must answer, and walks across the floor."
- "Escalation is informal: if the first person is busy, the event waits. Response times are unmeasured because nobody records when the call for help actually started."
cards:
- icon: "bell-alert"
title: "Alarms without an audience"
detail: "Stack lights and local alarms help only whoever happens to be nearby."
- icon: "chat-bubble-left-right"
title: "Events never reach team channels"
detail: "The tools people actually watch, phones, Teams, Slack, displays, are disconnected from the machines."
- icon: "arrow-path"
title: "No escalation path"
detail: "If the first responder is occupied, nothing routes the event to the next person."
- icon: "clock"
title: "Response time is invisible"
detail: "Without timestamps from event to acknowledgment, response cannot be measured or improved."

outcomeFirst:
heading: "From machine event to the right person, in seconds."
intro: "FlowFuse turns machine and operator events into routed notifications: andon displays, team-channel messages, SMS escalation chains, with acknowledgment and timing captured for every event."
dimensions:
- label: "Operational"
title: "Events routed, not broadcast"
detail: "The right role gets the right event on the channel they actually watch, with context attached."
- label: "Organizational"
title: "Escalation that runs itself"
detail: "Unacknowledged events climb the chain automatically; nothing waits on a walk across the floor."
- label: "Financial"
title: "Measured, shrinking response times"
detail: "Event-to-acknowledgment timing becomes a metric you can see and improve."

whyItMatters:
heading: "Downtime is often waiting time in disguise."
intro: "A meaningful share of every stop is the gap between the event and the right person knowing about it."
points:
- title: "Minutes of waiting hide in every stop"
detail: "Multiply the notification gap across every stop and shift; the total is a production line's worth of capacity."
- title: "Informal escalation fails on bad days"
detail: "Exactly when the floor is busiest, word-of-mouth routing breaks down."
- title: "Communication data improves staffing"
detail: "Knowing which events, where, at what times, shapes shift coverage and skill placement."

competition:
heading: "Why the usual approaches stall."
intro: "Andon exists in many forms; connected, routed, measured andon rarely does."
traps:
- label: "Hardware andon"
title: "Lights and towers, no routing"
detail: "Visual signals with no notion of who should respond or what happens if they do not."
- label: "MES call buttons"
title: "Locked to one vendor's screens"
detail: "Built-in call functions reach only the people logged into that system."
- label: "Group chat chaos"
title: "Everything posted to everyone"
detail: "Unrouted alerts train people to ignore the channel."

comparison:
without:
- title: "Events wait for a passerby"
detail: "Stack lights and shouts; response depends on proximity."
- title: "No record of response"
detail: "Event-to-fix timing unmeasured, unimprovable."
- title: "Every plant improvises"
detail: "Each site wires its own ad-hoc notification hacks."
with:
- title: "Events reach the right person in seconds"
detail: "Routed notifications with context, on channels people watch."
- title: "Acknowledgment and timing captured"
detail: "Response becomes a measured, managed metric."
- title: "One pattern across sites"
detail: "The same escalation flows deployed fleet-wide."

aiBuildLayer:
intro: "The FlowFuse Expert works on this use case with you, from routing logic to summarizing what happened overnight."
steps:
- title: "Describe it, get a starting flow"
detail: "Tell the Expert your events, roles and channels; it assembles a routing and escalation starting flow. Currently in open beta on FlowFuse Cloud."
- title: "Refine with in-editor assistance"
detail: "Function Builder and completions handle message formatting, shift calendars and escalation timers."
- title: "Own and adapt what you built"
detail: "The flow explainer documents routing rules so supervisors can read and adjust them without a developer."
note: "AI capabilities noted as beta are in open beta on FlowFuse Cloud at time of writing."

closingCta:
heading: "Close the gap between event and action"
description: "Talk to an expert about connected andon and escalation, or route your first event today."
---