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Predictive Maintenance, Reduce Defects, Greater Productivity—Find Your Answer with OPTRA Black Box

OPTRA Black Box is Designed to Solve Critical Production Challenges:

Process Replay: Replay past operations to precisely detect the root cause of anomalies
Early Anomaly Detection: Identify equipment issues by using master-pattern based anomaly detection and reduce unplanned downtime
Alarm Analysis: Analyze alarm timestamps to detect bottleneck alarms and minimize idle time across production line
Trend Analysis: Analyze operation time to build a strong AI model for predictive maintenance

Key Functional Features

Playback Feature

The following function synchronizes PLC signal data and field video footage on a unified time axis, enabling users to visually recreate past process events just as they occurred.

Select any time point to:

Trace signal behavior via an intuitive Gantt View
Understand PLC logic flow through the Ladder View
Review actual field conditions using synchronized Camera View

Trend Analysis

Trend Analysis function calculates daily statistics—including average, standard deviation, maximum, and minimum—based on ON/OFF signal durations or measured analog values.

Operation time is automatically extracted using start/end conditions
Measurement values are analyzed from regularly collected word data

All results are visualized as trend graphs to help users easily understand process changes over time.

Alarm Analysis

Alarm Analysis feature automatically calculates the time gap between alarm activation and release based on registered alarm tags.
Trace the logic paths to identify false or true alarm causes and highlight the final control contact in the sequence.
It visualizes key metrics including alarm duration, total downtime, and occurrence frequency—all in one dashboard.

Duplicate alarm durations are intelligently filtered out, allowing for accurate measurement of actual equipment downtime.

Master Pattern

Master Pattern function automatically learns the standard behavior of equipment by analyzing cycle-based control signals—capturing ON/OFF durations, operation sequences, and repetition patterns to generate a reference model for normal operations.

Once the baseline is set, real-time cycles are continuously compared against the master pattern to visually highlight any deviations from expected behavior.

Playback Feature

The following function synchronizes PLC signal data and field video footage on a unified time axis, enabling users to visually recreate past process events just as they occurred.

Select any time point to:

Trace signal behavior via an intuitive Gantt View
Understand PLC logic flow through the Ladder View
Review actual field conditions using synchronized Camera View

Trend Analysis

Trend Analysis function calculates daily statistics—including average, standard deviation, maximum, and minimum—based on ON/OFF signal durations or measured analog values.

Operation time is automatically extracted using start/end conditions
Measurement values are analyzed from regularly collected word data

All results are visualized as trend graphs to help users easily understand process changes over time.

Alarm Analysis

Alarm Analysis feature automatically calculates the time gap between alarm activation and release based on registered alarm tags.
Trace the logic paths to identify false or true alarm causes and highlight the final control contact in the sequence.
It visualizes key metrics including alarm duration, total downtime, and occurrence frequency—all in one dashboard.

Duplicate alarm durations are intelligently filtered out, allowing for accurate measurement of actual equipment downtime.

Master Pattern

Master Pattern function automatically learns the standard behavior of equipment by analyzing cycle-based control signals—capturing ON/OFF durations, operation sequences, and repetition patterns to generate a reference model for normal operations.

Once the baseline is set, real-time cycles are continuously compared against the master pattern to visually highlight any deviations from expected behavior.

Technical Advantages

Playback Analysis

Synchronize signal flow by using Gantt, Ladder, and Camera Views.
Quickly identify root causes and leverage visualized data for analysis, training, and issue resolution.

Trend Analysis

Visualize statistical changes based on operation durations or measured values, and detect anomalies exceeding baseline thresholds.
Enable early detection of equipment issues and support predictive maintenance strategies.

Alarm Analysis

Analyze alarm activation and release timing to monitor alarm duration, downtime, and frequency.
Trace the logic paths to identify false or true alarm causes and highlight the final control contact in the sequence.

Master Pattern

Learn standard equipment behavior through signal pattern analysis and automatically detect deviations from the norm.
Spot abnormal process flows early and strengthen quality control and process reliability.

Playback Analysis

Synchronize signal flow by using Gantt, Ladder, and Camera Views.
Quickly identify root causes and leverage visualized data for analysis, training, and issue resolution.

Trend Analysis

Visualize statistical changes based on operation durations or measured values, and detect anomalies exceeding baseline thresholds.
Enable early detection of equipment issues and support predictive maintenance strategies.

Alarm Analysis

Analyze alarm activation and release timing to monitor alarm duration, downtime, and frequency.
Trace the logic paths to identify false or true alarm causes and highlight the final control contact in the sequence.

Master Pattern

Learn standard equipment behavior through signal pattern analysis and automatically detect deviations from the norm.
Spot abnormal process flows early and strengthen quality control and process reliability.

Review

Solving Silent Stop Issue in Multi-Model Production Line

In this manufacturing facility, the process needed to follow a specific order to operate correctly. First, vehicle data had to be transmitted.
Then, the vehicle detection sensor had to turn ON for the vehicle data to be successfully delivered in the production line. However, at our client’s site, this order was not followed, causing random Silent Stops more than three times a day that were difficult to diagnose.
Even the PLC engineers couldn’t find the root cause. To analyze the issue, we used the Playback feature and .kept replaying the process using the Gantt Chart. Eventually, we discovered that the vehicle detection sensor was turning ON 0.3 seconds too early—a difference too small to notice. By tracing the related coil in Ladder View, we found that the issue was caused by a flaw in the PLC logic.
After modifying the controller logic, the problem was completely solved. As a result, our client was able to prevent major downtime

Solving Silent Stop Issue in Multi-Model Production Line

In this manufacturing facility, the process needed to follow a specific order to operate correctly. First, vehicle data had to be transmitted.
Then, the vehicle detection sensor had to turn ON for the vehicle data to be successfully delivered in the production line. However, at our client’s site, this order was not followed, causing random Silent Stops more than three times a day that were difficult to diagnose.
Even the PLC engineers couldn’t find the root cause. To analyze the issue, we used the Playback feature and .kept replaying the process using the Gantt Chart. Eventually, we discovered that the vehicle detection sensor was turning ON 0.3 seconds too early—a difference too small to notice. By tracing the related coil in Ladder View, we found that the issue was caused by a flaw in the PLC logic.
After modifying the controller logic, the problem was completely solved. As a result, our client was able to prevent major downtime

Service Process

01

Interview

Our engineers will be analyzing the on-site environment, identifying key operational issues, and assessing workflows and data flow.
Our team will define clear improvement goals and outline the core functional requirements for your needs.

02

Field Review

We evaluate the current data collection environment—including equipment, facilities, and network infrastructure.
This includes analyzing the technical feasibility, procurement conditions, and cost implications of connecting to your target devices.

03

Proof of Concept

Using real production data, we apply our solution to test specific use cases.
This phase helps assess system performance, verify the value, and identify the best approach for optimization.

04

Offer

We design a tailored system architecture and optimized data management strategy.
Based on the results, we provide a customized solution proposal with a step-by-step execution roadmap.

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