Shop Floor troubleshooting

Shop Floor troubleshooting

Common Shop Floor problems, what causes them, and how to fix them.

Permissions: Most fixes below are made on setup pages that need DataMagik - Builder. A Viewer can still open Data Source Enablement, Plant Readiness, OEE Diagnostics and the Write Outbox to find the cause, then pass it to a Builder.

Access and licences

• There is no Shop Floor menu, or a page says Shop Floor is not available. Your company's plan does not include the Shop Floor licence. Ask your DataMagik account contact.
• The Machines pages (OPC-UA Tag Map, PLC State Map and so on) are refused with a message about Shop Floor OT connectivity. Machine connectivity is a separate licence. The rest of Shop Floor works without it.
• The Asset Health section is missing from the menu. Asset Health needs its own licence on top of Shop Floor.
• A setup page is refused but boards open. Setup needs the DataMagik - Builder role. Ask your company administrator to grant it in User Manager.

A board is empty or a panel shows no data

• "No sites configured yet" or "No site is configured yet". Every board reads one plant. Add the site under Sites first.
• A Floor Console panel says no Plex data source is bound to it, or that it is switched off. Open Console Settings, choose a data source for the panel, and tick Show this panel. Bindings are per site, so check you are on the right site.
• A data source is not granted. Open Data Source Enablement and press Check for the site. For each ✗ Not granted row, grant that data source to the Plex API user the site uses, then check again. The Blocks: line shows which boards are waiting on it. For △ Shape mismatch, the listed differences show which fields changed in Plex.
• A site card shows "Data source credential missing" or "ODBC credential missing". The credential it names is no longer active. Edit the site and pick another, or create the credential again.
• No machine shows a live status, and the site shows "Live reads off". Live Plex reads is switched off for that site. Switch it on under Sites. History, hour blocks and OEE do not depend on it.
• "No workcenters have been pulled for this site yet", or a board says the site has no workcenters. Workcenters have not been brought in from Plex for this site. Check the site's credential and enablement, then contact DataMagik support to run the pull.
• A board says the site's status tree is not synced. Without Plex's status tree, no status can be told apart as downtime, so availability and downtime by line read zero. The tree is read from Plex for each site. Contact DataMagik support to sync it.
• The Plant Overview shows a list, not a map. The site has no plant map yet. Draw one under Plant maps.

Machines are missing from a board

• A machine is not measured, or an app cannot read it. It has no workcenter type. Classify it under Workcenter types, using guided setup or by choosing its type by hand.
• A line-filtered board, such as the Pace Board filtered by a line, shows nothing or misses machines. Only machines on that line are drawn. Open Areas and lines and move machines out of Machines not on a line onto the line.
• Hour by Hour finds no shift for a day. Pick another date, or check which shift cycle the workcenter is on in Plex.
• Shift Handover says "No shift has finished recently". Nothing on the site's rotas ended in the last three days. That is normal over a weekend the plant does not work.
• Figures look a day behind. The site has no timezone set, so reports close on a conservative 12-hour margin. Set Plant timezone (IANA) under Sites.

Run Plant Readiness for the site whenever figures look wrong. It grades what your Plex data supports and says What it would take to improve each area.

A captured reason did not reach Plex

Reasons and status changes captured on a board are queued, not sent immediately. Open the Write Outbox to see each write's state. Active Issues also lists "A reason write did not reach Plex". A workcenter that is not enabled for machine integration in Plex has status changes refused before they are sent. See Writing back to Plex.

Machine (PLC) data is not arriving

See Connecting PLCs and OPC-UA servers for the full setup.

• The connector is offline. Open Connectors → Connector Agents and check that the agent at the plant shows as online. If it is offline, check the machine it runs on, its service and its network.
• The site has no connector site. Until Connector site (for OT capture) is set on the site, OPC-UA tag capture cannot reach an agent.
• The OPC-UA endpoint cannot be reached. The agent connects to the machine, not the cloud, so the endpoint address on the OPC-UA Tag Map must resolve on the plant network where the agent runs.

Displays

• A display shows "Dark · last seen". It paired and then stopped checking in. Check the TV's power and network. It resumes its rotation on its own.
• The TV says "This display is not paired" or "no longer paired". Open /kiosk on the TV and enter a fresh token from Displays → Pair a screen. Tokens work once and expire after 60 minutes.
• The TV says "Nothing to show yet". No item in the saved rotation is switched on. Add or switch on an item, then press Save rotation.
• An application on a display says it has not been told who to run as. Set Runs as on the display.
• An external web page is blank. That website refuses to be embedded. It cannot be fixed from DataMagik.
• Only external pages can be added to a rotation. No shop-floor screen is registered and enabled. Register or turn on a screen under Screens.
• The remote says the TV is still counting an old number of pages. The TV picks up the saved rotation within a minute.

A screen answers not-found

It has been turned off, or it points at an application that was deleted. Open Screens and turn it on, or pick another application for it.