Remote Control and Mobile Monitoring Systems
Monitoring and safely controlling your production lines and machine status wherever in the world you are.
Remote control is not about running a production line from a distance; it is about seeing the state of the line, starting diagnosis the moment a fault occurs and being able to intervene safely when needed. Most of a stoppage is spent not on repair but on working out what the fault is. Contech builds systems with VPN infrastructure conforming to industrial cyber security standards, so that diagnosis begins before anyone sets off.
The system is designed by first deciding what data to monitor. Which points of the line, which process variable values and which alarms will generate notifications are chosen by looking at the plant’s historical downtime data; monitoring every signal causes the important ones to disappear. At the connection layer, an industrial router or VPN appliance is used. PLCs and HMIs are never exposed directly to the internet under any circumstances; access is made solely through a VPN tunnel. The automation network is separated from the office network and traffic between them is restricted, because a vulnerability on the office side must not reach the production network. Authorisation is granted per person and connection logs are kept, so who connected when and what they did remains traceable. Remote write access is managed separately from monitoring access — most users only need to see. Unused ports are closed and default passwords changed. For mobile access, separate screens are designed for operators and management. Management sees output counts, downtime durations and efficiency summaries; the technical team sees alarm history, I/O states and process variables. Alarm notifications are prioritised, with production-stopping events and conditions merely to be watched sent through different channels — otherwise users soon switch every notification off. Adding remote monitoring to an existing line usually requires no reprogramming; suitable hardware, network separation and defining the data to be monitored on the PLC side are enough. After installation the system is tested against a real fault scenario: an alarm is generated and both notification delivery and remote connectivity are verified.
- Monitored data chosen from historical downtime records — the right signals, not every signal.
- Industrial VPN infrastructure; PLCs and HMIs never exposed directly to the internet.
- Automation network separated from the office network with restricted traffic between them.
- Per-person authorisation with connection logging.
- Remote write access managed separately from monitoring access.
- Separate mobile screens for operators and management.
- Prioritised alarm notification, with critical events on a different channel from notices.
- Remote diagnosis by technical staff outside shift hours
- Central monitoring across multi-site operations
- Remote technical support on machines sold abroad
- Production efficiency and downtime reporting for management
Does remote access create a security risk?
Not when it is set up correctly. The PLC is not exposed to the internet; access runs over VPN, the automation network is separated from the office network, rights are granted per person and connections are logged. What is risky is not remote access itself but omitting these measures.
Can it be added to our existing line?
In most cases yes, and without reprogramming the line. A suitable industrial router or VPN appliance, network separation and defining the data to be monitored on the PLC side are enough.
Can we start the machine remotely?
It is technically possible, but write access is managed separately from monitoring and who receives it is decided together with the plant. In most scenarios the need is monitoring; remote starting is kept limited on safety grounds.
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