Haltless connects to your existing PLCs and historians over OPC UA, Modbus TCP, CSV, or JSON, scores machine health with an explainable formula instead of a black-box model, and ties every alert into a full CMMS workflow with digitally signed work orders.
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From reactive firefighting to early warnings, days before they happen.
Most predictive-maintenance tools answer "what" but not "why". A neural net says a machine is at risk, your operators stop trusting it after the third false positive, and your auditors cannot reproduce the score. Haltless takes the opposite approach: three deterministic anomaly detectors running in parallel, a published deduction table, and a health score that always traces back to specific events.
Haltless installs a small Python edge agent on any Linux machine alongside your equipment. It reads your signals over OPC UA, Modbus TCP, CSV file watch, or JSON file watch, computes a baseline automatically, and runs three deterministic anomaly detectors over every reading. Your team gets a specific event and a specific signal, not just "something is wrong".
From robotic assembly to continuous-flow processing, Haltless adapts to your operating context.
Robotic lines, stamping presses, weld cells. IATF 16949 traceability.
Learn moreTurbines, transformers, substations. IEC 61850 over OPC UA.
Learn moreFilling, packaging, CIP systems. HACCP-ready signed records.
Learn morePresses, mills, forges, crushers. ISO 9001 work-order traceability.
Learn moreReactors, fermenters, filling lines. FDA 21 CFR Part 11 signoffs.
Learn moreInjection molders, extruders, chillers. ISO 9001 work-order traceability.
Learn moreFour input protocols: OPC UA, Modbus TCP, CSV file watch, and JSON file watch. The edge agent runs on any Linux box next to your machines and survives weeks of WAN outage thanks to a local SQLite buffer that auto-flushes when connectivity returns. No new sensors, no proprietary hardware.
Three deterministic detectors run in parallel: a z-score against a rolling baseline, an EWMA that adapts to gradual drift, and a rate-of-change check that catches velocity anomalies even when the absolute value is still in range. The 0 to 100 health score follows a published deduction table, not a black-box model.
Every alert can open a work order with priority, parts pulled from inventory, an assigned operator, and a digitally signed completion record. SHA-256 over the canonical payload makes the signoffs FDA 21 CFR Part 11 and ISO 9001 compatible. Ten outbound notification channels keep the rest of your stack in the loop.
“Every health score in Haltless traces back to specific events through a published formula, not a neural net. Operators trust it because they can reproduce it; auditors trust it because the math is on the page.”
Haltless plugs into the equipment and tools you already run, no new sensors required.
Four input protocols
OPC UA · Modbus TCP · CSV · JSON
Ten notification channels
Slack · Microsoft Teams · PagerDuty · Opsgenie …
Three ERP adapters
SAP · Oracle · Microsoft Dynamics
Install the edge agent on a Linux box near your machines, point it at your existing PLCs, and your fleet view is live in the browser before the day is over. No consultants, no proprietary sensors, no multi-week integration sprint.
A small Python edge agent runs on a Linux box on the OT network. Configure each ingest source over OPC UA, Modbus TCP, CSV, or JSON. Telemetry is buffered locally in SQLite, so the agent keeps collecting even if the WAN drops for days.
The agent forwards readings over an authenticated, TLS-pinned control channel into the US-hosted, multi-tenant cloud. Three deterministic anomaly detectors score every machine in near real time, and the WebSocket layer pushes updates to your browser in under 100 ms.
Anomalies fire alerts that can open a CMMS work order in the same platform, with parts pulled from inventory, a digitally signed completion record, and a tamper-evident HMAC-SHA256 audit chain retained for seven years.
Connect Haltless to your existing PLCs, validate the explainable health score on your own equipment, and we come back with a tailored quote. No new hardware, no proprietary sensors, no consultants.
