PLC program changes
Traditional projects often require control-program modifications, additional testing and the involvement of multiple specialists.
SystemSmart / TraceSmart
TraceSmart – a modular traceability system for manufacturing
TraceSmart operates as a standalone system or extends an existing MES. It collects, interprets and records production data without modifying PLC programs, providing complete product history, automated reporting and process control in one environment.
No PLC program changes
Integrated database, reports and operator panel
Integration with MES, ERP, SCADA and customer systems
Complete hardware and software module
Modular expansion from a single station
Support and remote-supervision packages, including 24/7
ST01 · Online
Active product
FRAME_001
Result
OK · 5.1 bar
1 / 5
Data directly from the PLC, with no changes
Data source
Line / PLC / devices
TraceSmart Platform
Standalone or with
MES / ERP / SCADA
TraceSmart interprets process data, stores it in its integrated database and makes it available to operators, quality teams and higher-level systems.
Identification
Data interpretation
Product history
Reports
Validation and interlocks
Project experience with manufacturing plants and industrial brands
The challenge
Why traditional traceability projects are costly and difficult to expand
Solutions built from scratch often combine multiple separate tools, suppliers and integration layers. This extends commissioning time and makes future changes more difficult.
Long project timelines
Building dedicated applications, databases and panels from scratch can take months.
High integration costs
Separate PLC, SCADA, SQL and reporting systems create additional licence and engineering costs.
Fragmented information
Results, measurements and product data remain scattered across different files or devices.
Complex reporting and audits
Manually compiling product history takes time and increases the risk of missing information.
Why TraceSmart
One hardware and software platform. Complete data flow.
TraceSmart standardises the key elements of deployment while remaining flexible for the customer’s process, devices and infrastructure.
Integration without PLC changes
We acquire existing process signals without rebuilding the PLC program or interfering with machine logic.
Shorter deployment time
Standard hardware modules and a ready platform reduce the amount of engineering that must be completed from scratch.
Complete product identification
We combine products, components, batches, stations, measurements and operators into one complete history.
Automated data interpretation
Digital and analogue signals and device data are converted into process events, results and statuses.
Reports and product history
Information is available immediately after each operation and can be exported or transferred to customer systems.
Lower deployment cost
Standardised hardware, software and commissioning reduce both integration and future expansion costs.
Complete solution
Complete TraceSmart hardware and software module
TraceSmart is more than an application. Every deployment is based on a module prepared by SystemSmart and tailored to the customer’s process. The module collects line data, interprets it, stores it in the database and makes it available to operators, quality teams and higher-level systems.
Industrial cabinet or enclosure
Industrial PC and Ethernet switch
HMI panel and operator interface
I/O modules and signal isolation
TraceSmart Runtime and database
TraceManager, VPN and documentation
The equipment scope is selected after analysing the line and available signals. The illustration shows an example module configuration.
I/O modules
HMI panel
VPN / service
Database
TraceSmart Module
Industrial PC
Industrial switch
Digital and analogue I/O
TraceSmart Runtime
Power supply and protection
Data flow
How TraceSmart collects and processes production data
The core approach is non-invasive acquisition of available process signals. Where the customer’s infrastructure provides a secure read-only interface, the system can also use network communication.
PLCs and machines
I/O and sensors
Scanners / RFID
OCR / scales
↓
TraceSmart Runtime
interpretation, validation, events
interpretation, validation, events
↓
Database
Operator panel
Reports
MES / ERP / SCADA
Integration without modifying the PLC program
TraceSmart acquires signals from digital and analogue I/O, devices and agreed communication protocols. The PLC program remains unchanged, while any installation work is completed during an agreed service window.
- 24 V digital signals and potential-free contacts
- 0–10 V and 4–20 mA analogue signals
- Sensors, scales, cameras, scanners, RFID and OCR
- Reduced deployment impact on line operation
Modbus TCP / RTUOPC UA / DAS7 ReadEtherNet/IPMQTTREST APISQL / ODBCCSV / FILE
From assessment to production
Deployment delivered by the SystemSmart team
The customer receives more than software: a complete deployment covering process analysis, hardware selection, configuration, testing, commissioning and ongoing support.
01
Process and line assessment
We analyse the production flow, devices, products and information that should be recorded.
02
Signal mapping
We identify available I/O, device data and secure communication options.
03
Module selection
We select the hardware, interfaces, panels, identification methods and software functions.
04
Installation and configuration
We install the module and configure stations, process rules, users and reports.
05
Testing and validation
We verify data acquisition, process logic, product flow and integrations.
06
Commissioning and training
We commission the production system, train users and transition to the agreed support arrangement.
Delivery time: typical deployments take several days to several weeks, depending on the number of stations and process complexity. The exact schedule is confirmed after a technical assessment.
Modular architecture
Select the TraceSmart modules for your process
The platform can be launched at a single station and expanded with additional functions, devices and lines. All modules operate within one environment and use a shared database.
TraceSmart Core
Process runtime, shared database, station handling and central product model.
TraceManager
Administration and configuration of stations, I/O points, devices, users and versions.
Operator panel
PartId scanning, operation launch, messages, results and station mode.
Identification and genealogy
Barcodes, QR, RFID, batches, parent–child relationships and complete component history.
Reports and dashboards
Filters, OK/NOK/BLOCKED/ERROR statuses, quality analysis and data export.
Validation and Lua
Process rules, testing, versioning and logic activation without rebuilding the application.
Rework, FIFO and interlocks
Control of process sequence, missing components, repeated operations and process blocking.
MES, ERP, SCADA and API
Bidirectional data exchange through API, SQL, ODBC, MQTT or files.
Scanners and RFID
Support for barcode identification, RFID carriers and station devices.
OCR and vision systems
Reading labels, markings and visual data as part of the product history.
Alarms and runtime log
Current events, messages, diagnostics and station operation history.
Users and roles
Permissions, operator activity, login history and audit trail.
Genealogy and quality
Complete product history by PartId
TraceSmart reconstructs the production path of every product, component or batch. Searching by PartId shows stations, operations, measurements, statuses, users and nonconformity reasons.
PartId, batch and production order
OK / NOK / BLOCKED / ERROR
Measurements, station and time
Operator and configuration version
Parent–child genealogy
Rework, FIFO and runtime log
The data supports audits, complaints, quality analysis, root-cause identification and process optimisation.
PART ID
SHAFT_447
PRODUCT COMPLETESHAFT_447
21:14:08ST04_FINAL · final inspectionOK
21:13:31ST03_ASSY · 8 assembly stepsOK
21:12:44ST02_TORQUE · tightening torque6.2 Nm
21:11:19ST01_PRESSURE · pressure test5.1 bar
✓ 4 stations · 0 missing operations · configuration v3.4
Standalone or integrated with higher-level systems
TraceSmart operates independently or extends an existing MES
The plant retains its existing IT/OT environment while TraceSmart supplies structured traceability data required by production, quality and higher-level systems.
Already have an MES? There is no need to replace it
TraceSmart can operate as a data-acquisition, interpretation and structuring layer. It then sends PartId, operation results, measurements, status, time, station, nonconformity reasons and product genealogy to MES, ERP or SCADA.
- Bidirectional exchange through API, SQL, ODBC or files
- Data from multiple stations in a consistent format
- Option to transfer information to central reporting
- Integration aligned with the customer’s IT standards
No MES? TraceSmart works as a standalone system
An integrated database, operator panel, TraceManager, reports, PartId search, station configuration, process validation and data export provide complete traceability without purchasing a large MES platform.
Control systems
SiemensRockwellSchneiderOmronBeckhoffABB
Systems and data
MESERPSCADASAPSQL ServerPower BI
Control and continuity
Security, versioning and complete change control
In a production environment, data must be repeatable and protected against unauthorised changes. TraceSmart records configuration versions, user activity, active logic and the execution context of each operation.
- Production can run on an approved configuration
- Rule and parameter changes remain in the history
- Data is buffered if a connection is lost
- An on-premises data model can securely transfer selected information to the cloud
Roles and permissions
Role-based access, login history and operator activity.
Versions and approval
Script and configuration versioning with approval before production use.
Backups and buffering
Backups, local storage and automatic resumption of data transfer.
Secure access
Encrypted connections, audit logs and remote diagnostics through VPN.
The system in practice
A clear interface for operators, quality teams and administrators
One platform covers daily station operation, process configuration, product-history search, reporting and diagnostics.
Operator panel — simple for everyday use
The operator sees only what is needed: the active product, latest test result and event log. This is how a TraceSmart-connected station works in daily production.
✓Data directly from the PLC, with no program changes
Active product
FRAME_001
Latest measurement
5.1 bar
Process completed successfully
Scan or enter PartId…|
Runtime online
Station and I/O-point configuration
Define devices, signal direction, channels, filtering and measurement ranges.
Stations
Components
Devices
Validation
Approval history
| PointName | DeviceCode | Type | Channel | Debounce |
|---|---|---|---|---|
| PressureValue | AI01 | Analog | 0 | — |
| ResultOk | DI01 | Digital | 1 | 150 ms |
| AlarmLamp | DO01 | Digital | 2 | — |
Lua logic editor and versioning
Process rules can be tested with simulated inputs, versioned and activated after approval.
-- pressure and component validation
if AI("PressureValue") >= 4.5 and HasRequiredChildParts() then
SaveResult("OK")
else
SaveResult("NOK", "PROCESS_VALIDATION")
end
if AI("PressureValue") >= 4.5 and HasRequiredChildParts() then
SaveResult("OK")
else
SaveResult("NOK", "PROCESS_VALIDATION")
end
Product trace and genealogy
Search PartId, statuses, measurements, product flow, components and operation history.
FRAME_001OK
20:56ST03_FINALOK
20:55ST02_TORQUE6.2 Nm
20:54ST01_PRESSURE5.1 bar
Reports and data export
Filter by dates, stations and statuses and export results for further analysis.
1 247
Results
1 221
OK
18
NOK
CSV
Export
| PartId | Station | Result | Measurement |
|---|---|---|---|
| FRAME_001 | ST01 | OK | 5.1 bar |
| FRAME_002 | ST01 | NOK | 3.2 bar |
Runtime, diagnostics and FIFO queues
Current station status, events, product queues, result reasons and system logs.
Runtime monitor
Runtime log
FIFO queues
Result reasons
[21:02:03] ST01 · part FRAME_005 activated
[21:02:05] AI PressureValue = 5.0 bar
[21:02:06] result OK saved
[21:02:07] FIFO → ST02 position 4
Approach comparison
TraceSmart compared with traditional traceability projects
| Area | Traditional project | TraceSmart | Benefit |
|---|---|---|---|
| PLC integration | Frequent program changes, testing and coordination between multiple parties | Signal acquisition without modifying PLC logic | Reduced risk and fewer changes on the production line |
| Deployment time | Applications and architecture built from scratch | Ready, standardised platform | Faster commissioning after a technical assessment |
| Costs | Multiple tools, licences and contractors | One platform with selected modules | Lower and more predictable expansion costs |
| Product data | Information scattered across devices and files | Complete history from raw material or component to finished product | Faster quality and complaint analysis |
| Reporting | Manual summaries or additional applications | Reports, filters, export and integration | Less manual work |
| Expansion | Costly changes across multiple system components | Modules, rule versions and a shared database | Expansion without rebuilding the system |
Applications
TraceSmart for multiple manufacturing industries
The modular architecture adapts the platform to different products, quality standards, identification methods and production models.
Automotive
Component identification, process parameters, genealogy and rework.
Electronics
Tracking serial numbers, tests, assembly and quality control.
Food and beverage
Batches, raw materials, dates, lines, inspections and rapid root-cause identification.
Pharmaceutical
Configuration control, rule versions, audit trail and process data.
Machinery and equipment
Assembly history, used components and final testing.
Packaging
Batch identification, marking verification and OCR integration.
Aerospace
Documentation of operations, materials and quality-control results.
Energy
Recording events, measurements, configurations and process work.
Business value
Benefits of deploying TraceSmart
Faster audits and complaint handling
Product and process data is available in one place without manually combining reports.
Less manual work
Automatic data acquisition reduces manual result entry and spreadsheet creation.
Lower integration costs
A ready platform and no PLC changes reduce consulting and programming work.
Faster issue analysis
PartId history helps identify the station, result, measurement and nonconformity reason.
Improved quality control
Process validation and interlocks help detect nonconformities before the next stage.
Scalable without rebuilding
The system can be expanded with additional stations, lines, plants and integrations.
Support and remote supervision tailored to production requirements
Technical-support and remote-supervision packages are available, including 24/7 options. Service scope, specialist availability and guaranteed response time are defined in the service-level agreement.
Remote support
Diagnostics
SLA packages
Customer testimonials
What companies using TraceSmart say
Real experience from production launches, PLC integration and daily reporting.
“TraceSmart was deployed on three lines within three weeks. Operators adopted the interface immediately, and the ISO audit was completed without any issues.”Production ManagerFood industry, Poland
“We did not need to modify the PLC programs — that was the biggest advantage. The entire deployment was predictable and caused no production-line downtime.”Automation EngineerIndustrial machinery manufacturer
“We now have a complete history for every product. Reports are generated automatically, ERP integration works reliably and 24-hour support gives us peace of mind.”Quality DirectorAutomotive industry
Poland and Europe
TraceSmart deployments in Poland and across Europe
SystemSmart provides assessment, installation, commissioning and support for manufacturing plants in Poland and other European countries.
- On-site assessment, installation and commissioning
- Multilingual interface and documentation
- Training and support in Polish and English
- Remote diagnostics and service support
- Solution standardisation across multiple customer plants
Local and multi-site deployments
Remote support and standardisation
Predictable investment
How much does a TraceSmart deployment cost?
Standardised hardware, software and commissioning make the cost lower and more predictable than systems built from scratch.
Larger projects covering additional stations, lines, devices or MES and ERP integration are priced individually after a technical assessment.
Book a free deployment assessmentSingle station
from PLN 20,000
Scope confirmed after technical assessment
Number of signals
Integration method
Identification and devices
HMI panels
Reports and dashboards
MES / ERP / SCADA
FAQ
Frequently asked questions about TraceSmart
Answers about functionality, integration, security, deployment, support and pricing.
System and functions
TraceSmart is a modular production traceability system combining industrial hardware, software, an integrated database, an operator panel, TraceManager and reporting tools. It can operate as a standalone system or extend an existing MES.
No. TraceSmart includes its own database, product search, operator panel, process configuration, reports and data export. Integration with MES, ERP or SAP is optional.
The system can record PartId, batch and production-order numbers, station, OK/NOK/BLOCKED/ERROR results, measurements, operator, operation time, failure reason, configuration version, component genealogy, rework history, FIFO queues and runtime logs.
Yes. TraceSmart can enforce process order, manage FIFO queues, record rework and block a product or subsequent operation when process requirements are not met.
Yes. The system can start with one station and then be expanded with additional stations, lines, identification modules, reports and integrations without rebuilding the entire solution.
Integration and deployment
No. The core approach is to acquire available process signals without modifying the PLC program or interfering with the machine-control logic.
Data can be collected from digital and analogue I/O, potential-free contacts, sensors, scales, scanners, RFID, OCR and secure communication interfaces provided by the customer’s infrastructure.
The supported scope includes Modbus TCP/RTU, OPC UA/DA, S7 Read, EtherNet/IP, MQTT, REST API, SQL, ODBC, CSV, 24 V signals, 0–10 V and 4–20 mA. The final integration method is selected after a technical assessment.
Typical deployments take several days or weeks. The exact timeline depends on the number of stations, available signals, connected devices and process complexity, and is confirmed after a technical assessment.
Integration does not require PLC program changes. The scope of installation work and any short service window are agreed individually, depending on the customer’s installation.
Depending on the project, the module may include an industrial cabinet or enclosure, industrial PC, switch, HMI panel, power supply and protection, I/O modules, signal isolation, VPN connectivity, database, TraceSmart Runtime, TraceManager and the operator panel.
Yes. The platform can exchange PartId, operation results, measurements, statuses, times, failure reasons and product genealogy with higher-level systems through an API, database or agreed data-exchange format.
Security, support and pricing
The standard model is an on-premises installation within the plant infrastructure. Selected information can also be transferred to the customer’s cloud, central database or reporting system.
TraceSmart supports roles and permissions, login and change history, configuration versioning and approval, audit logs, backups, data buffering, encrypted connections and secure VPN access.
Yes. Technical-support and remote-supervision packages are available, including 24/7 options. The service scope and guaranteed response time are defined in the service-level agreement.
The cost of a single-station deployment starts at PLN 20,000. Larger deployments, additional devices and MES or ERP integrations are priced after a technical assessment.
Yes. We deliver projects in Poland and other European countries, providing assessment, commissioning, documentation, training and remote support in Polish or English.
Let’s discuss your production line
See how TraceSmart can support your process
During the initial discussion, we will identify data sources, define the required product history, review integration options and agree the next steps for a technical assessment.
Available-signal analysis
Proposed modules and architecture
Initial scope and schedule