Manufacturing Process Monitoring

Gain real-time visibility across every production line. Primate’s manufacturing process monitoring system unifies machine, sensor, MES, and quality data into one live view so operators can detect issues faster and keep output on track.

Control room operator analyzing real-time system data and geospatial visualization on large displays

From Weeks to Hours: $150K Saved Every Year

Primate’s Network Model lets operators complete grid updates in 4 hours instead of 80, cutting dependency on engineers, eliminating backlogs, and typically saving over $150,000 per year in labor costs.

$150K+

annual labor savings

96%

faster update time

Real-Time Monitoring vs $6.7B Blackout

During the 2003 Northeast blackout, alarm failures left operators blind for over 90 minutes.Primate’s real-time EMS health monitoring would have caught the failure instantly, preventing cascading outages and billions in economic losses.

$6.7B

loss avoided

90+

min faster operator response

Preventing $1M-a-Day Penalties

NERC violations for missed contingencies can cost utilities millions daily. Primate continuously monitors data quality and system limits, instantly flagging potential breaches to help keep operations compliant and penalty-free.

$1M/day

fines prevented

3

key NERC standards covered

One Visualization. $100M in Mission Costs Saved

A detected anomaly nearly grounded a million-dollar launch. Primate’s visualization revealed it was outside the critical zone, preventing an unnecessary cancellation and saving hundreds of millions in wasted preparation.

$100-$150M

loss avoided

0

false aborts

Turning $1.7M Outages Into Minutes of Downtime

Average grid outages last 5.8 hours and cost $1.7M in downtime and penalties. Primate’s fault detection helps operators isolate and resolve issues fast, often restoring power in minutes instead of hours.

$1.7M

saved per outage

5.8hrs = minutes

recovery time

Stopping $300K-an-Hour Downtime Before It Starts

Each hour of downtime costs electric utilities around $300K. Primate’s continuous visualization spots anomalies before they escalate, keeping systems online, reliable, and efficient around the clock.

$300K/hr

loss prevented

24/7

intelligent alarming

Operators in a control room monitoring real-time system data on a large video wall with visual indicators

Real Insight Into Every Stage of Production

Manufacturing teams operate under constant pressure to keep lines moving, maintain quality, prevent downtime, and respond quickly when conditions shift. Yet, critical data lives across multiple systems. 

MES captures production metrics, SCADA collects machine data, quality tools track defects, and environmental sensors run separately. Operators get slices of the truth, not the full picture.

Primate unifies all of it into one real-time operational view. Every machine, sensor, line, and condition comes together on a single display so operators can detect anomalies earlier, optimize performance, and maintain complete process awareness from start to finish.

Simplify Your Entire Manufacturing Process

Primate consolidates SCADA, MES, PLC data, sensors, quality systems, machine telemetry, energy usage, maintenance data, and environmental conditions into a single operational interface. Operators get a live, constantly updated view of line performance, machine health, alerts, and deviations from normal patterns.

Design role-specific operational dashboards

Real-time process visibility

Configure priority-based alert displays

Unified data from every production system

Access historical trends through interactive displays

Intelligent alerts for quality or performance anomalies

Enable team-wide situational awareness with collaborative visualization tools

Clear visuals across desktops and large display

Enable team-wide situational awareness with collaborative visualization tools

Faster detection of equipment issues and bottlenecks

Want to see how much downtime you could prevent?


Key Capabilities for Pipeline Operations

Icon of connected nodes representing unified control room integration

Multi-System Integration

Primate merges MES, SCADA, PLC data, sensors, energy systems, quality tools, and maintenance platforms into one real-time view without reconfiguring your infrastructure.

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Anomaly Detection

Custom logic correlates machine readings, temperature changes, vibration data, cycle times, throughput, and quality indicators to surface true process deviations.

magnifying glass icon representing geospatial and external data integration

Intelligent Alerting

Tiered, rule-based alerts notify operators the moment conditions shift, highlighting the process changes that require immediate action.

Bar chart icon symbolizing complex network data analysis for decision-making

Advanced Visual Intelligence

Operators switch between line overviews, machine schematics, and facility-level maps, all with clear rendering at any scale.

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Historian and Replay

Replay events for downtime investigations, quality audits, training, or root cause analysis, with full visibility into how conditions developed.

Stacked documents icon representing seamless access to crucial system insights

Security & Compliance

Monitor access, activity, and operational logs inside a secure, compliant visualization environment that supports industrial standards.

High-Value Use Cases

Manufacturing teams benefit most when data forms a complete picture. With Primate, operators gain faster insight and clearer decision support across every process.

Real-time monitoring of physical security and cyber threats

Track defects, trends, and machine-related quality factors in real time.

Integrated safety monitoring including man-down alerts and crew safety status

Monitor temperature, vibration, cycles, load, and operational anomalies across all stations.

Automatic data quality validation and system health checks

View output rates, cycle times, delays, and bottlenecks with instant clarity.

Seamless integration of field device communications and monitoring

Display temperature, humidity, airflow, and contamination risks directly alongside machine data.

Seamless integration of field device communications and monitoring

See early indicators of failures or slowdowns and reduce time to intervention.

Control room operator monitoring real-time system data and network schematics on multiple displays

Integrated Data for Better Context

Linking machine telemetry, MES, maintenance systems, and historian data gives operators immediate context behind every shift in production. Live readings show what is happening, maintenance logs show why it may be happening, and everything feeds into a single operational view.

Historian data builds on this by revealing patterns and early warning signs that real-time displays alone cannot catch. Operators compare current conditions to past trends, replay events, and understand how performance issues develop. Together, these sources create a complete, reliable picture of manufacturing health.

Technology Optimized for Manufacturing

Primate combines different technologies to process, render, and display manufacturing conditions instantly, giving operators a reliable picture of production health, machine state, and environmental impacts across every line.

TileViewer

Real-Time Interface

Access critical system information from anywhere through:

Desktop workstations

Desktop workstations

Video wall displays

Video wall displays

Mobile devices

Mobile devices

Remote access points

Remote access points

Emergency backup displays

Emergency backup displays

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BlackBoard™

Visualization Processor

Purpose-built for control room environments, delivering:

High-performance graphics processing

High-performance graphics processing

Multi-screen synchronization

Multi-screen synchronization

Interactive control functions

Interactive control functions

Remote access capabilities

Remote access capabilities

Real-time data updates

Real-time data updates

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TileBuilder

Display Engine

Transform complex data into clear visualizations with:

Optimized rendering for any screen size

Optimized rendering for any screen size

Seamless zoom level integration

Seamless zoom level integration

Automatic data point rendering

Automatic data point rendering

Lightning-fast navigation

Lightning-fast navigation

Custom display formatting

Custom display formatting

Learn More
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Full Deployment & Integration

Primate fits your existing factory systems and scales with your needs. Our team adapts to your operational environment to ensure smooth integration, consistent performance, and a deployment process that matches how your facility already works. You get:

Proprietary network continuity model

Production and control room display design

Study, state estimation, and contingency analysis results visualized in real-time

Integration engineering and API work

Monitor network topology and flow constraints automatically

Custom calculations and alert logic

Track unit fuel supply limitations and market pricing dynamics

End-to-end validation

Validate data quality across all integrated systems

Ongoing maintenance and support

Manufacturing Process Monitoring Done Right

Production teams need clearer visibility and faster insight to maintain safety, quality, and output. Primate delivers a unified monitoring system built around real operational conditions and real factory workflows. If you are ready to upgrade your process awareness across every line, it starts here.

Ready to try Primate’s manufacturing process monitoring system?

Request a Demo