Emerson Movicon Pro.Lean is an OEE and production data collection module built on the Movicon.NExT SCADA PRO platform. It automatically collects production metrics — good units, rejects, uptime, and downtime — directly from PLCs, CNCs, PACs, and other automation devices, then calculates availability, performance, and quality KPIs aligned with ISO 22400. The result is a single source of truth for production performance, accessible via HTML5 dashboards from anywhere in the plant or remotely.

What production metrics does Pro.Lean collect?

Pro.Lean captures total good units, total rejects, production availability, uptime, batch code, product code, and theoretical production rate for each monitored work center. Up to 32 downtime causes can be configured per OEE — expandable with an additional license option — enabling operators to categorize stoppages with a single tap for accurate root-cause analysis. Alarms (up to 32 per OEE, also expandable) trigger when KPIs deviate from targets, ensuring issues are flagged in real time rather than discovered days later in a report.

How is Pro.Lean deployed and what does it require?

Pro.Lean requires a Movicon.NExT 3.1 or later PRO Runtime license sized for the number of OEE work centers. The built-in configuration wizard automates project creation and SQL Server database setup, typically reducing deployment to a few days per plant — even in multi-site rollouts spanning over 100 facilities. The module reads data from existing automation devices using Movicon.NExT's native I/O drivers, requiring no additional hardware or network changes. Reports and dashboards are served via the Movicon.NExT HTML5 Web Client to any standard browser.

What can I do with the collected OEE data?

The SQL Server calculation database stores all production data for custom querying and integration with MES or ERP systems. Built-in reports cover shift-based OEE trends, downtime Pareto analysis, and production batch traceability. The HTML5 dashboards display real-time OEE scores, machine status, and alarm conditions — giving production managers, maintenance teams, and plant leadership a shared operational picture without installing client software on every workstation.