Model Your Plant

AudienceCompany Owners, Plant Admins, Process Engineers

Required PermissionsCompany or plant configuration permissions

Estimated Time8 min read

Demo Referencecemento-valladolid

Before ingesting telemetry or building dashboards, Model Your Plant in OTCognix. Establishing your physical and organizational hierarchy first ensures every tag, alarm rule, downtime event, KPI calculation, and Ask Cogni AI insight automatically inherits accurate operational context.

Complete Asset & Organization Hierarchy

Company (Tenant boundary, billing & shared standards)
  ├── Company Resources (Downtime Catalogs, Machine Templates, Company Permissions)
  └── Plant (Physical site, time zone, operational day, shifts, plant users)
        ├── Plant Resources (Local or inherited Catalogs & Templates, Digital Sets)
        └── Process Area (Functional department, e.g., Raw Grinding, Kiln, Packaging)
              └── Production Unit (Operating line / cell, e.g., CM01, KL01)
                    └── Machine (Physical asset built directly or from a Machine Template)
                          └── Tags (Interface, Calculated, and Manual signals)

What Each Building Block Represents

Concept	What It Is	Why It Matters
Company	The top-level tenant boundary for an enterprise or business group.	Isolates plants, teams, and shared engineering standards across sites.
Plant	A physical industrial facility under a company (e.g., Cemento Valladolid).	Anchors local time zone, operational day start, shift schedules, and site user permissions.
Process Area	A major operational zone within a plant (e.g., Raw Grinding, Kiln Line, Packaging).	Groups related lines so supervisors and cost reports roll up by department.
Production Unit	A continuous operating cell or production line inside a process area (e.g., RM01 - Raw Mill 01, KL01 - Kiln 01).	Serves as the primary equipment context for telemetry ingestion, OEE, and alarms.
Machine	An individual piece of physical equipment inside a production unit (motors, gearboxes, fans, pumps).	Associates sensor tags, components, and mechanical limits to real maintainable assets.
Digital Set (Digital State)	A named lookup dictionary translating numeric PLC/SCADA integers into human states (e.g., 0 = Stopped, 1 = Running, 2 = Fault).	Keeps dashboards, timeline bars, downtime triggers, and AI analysis readable everywhere.

Shared Company Standards vs. Plant Inheritance

OTCognix lets companies standardize engineering libraries once and roll them out across multiple plants:

• Downtime Catalogs: A 3-level taxonomy (Stoppage Class -> Failure Type -> Failure Reason) defined at the Company level or locally per Plant.
• Machine Templates: Reusable equipment blueprints defining standard Components and Expected Tags so every similar mill, pump, or fan across plants monitors identical KPIs.
• Enabling inheritance switches (Use company downtime catalogs / Use company machine templates) keeps multi-plant reporting uniform without duplicating setup work.

Recommended Setup Sequence & Visual Guides

1. Companies (Organization & Shared Standards)

• Create, Edit, and Delete a Company
• Manage Company Downtime Catalogs
• Manage Company Machine Templates
• Grant Permissions for Downtime Catalogs & Machine Templates

2. Plants (Site Operations & Access)

• Create, Edit, and Delete Plants
• Configure Plant Shifts
• Manage Internal Plant Users
• Manage External Plant Users
• Manage Plant Downtime Catalogs
• Manage Plant Machine Templates

3. Hierarchy, Digital States & Formulas

• Create, Edit, and Delete Process Areas
• Create, Edit, and Delete Production Units
• Create, Edit, and Delete Digital Sets (Digital States)
• Calculated Tag Formulas