Digital Factory API Documentation

Business Purpose

Station Specifications

Modbus Register Map

Address	Name	Type	Description
40001	State	uint16	0=OFF, 1=IDLE, 2=RUNNING, 3=FAULTED, 4=BLOCKED, 5=STARVED
40002	Step	uint16	0=IDLE, 1=LOADING, 2=WASHING, 3=UNLOADING
40005	PartsProduced	uint16	Cumulative parts washed
40006	PartsGood	uint16	Successfully cleaned parts
40007	PartsBad	uint16	Parts requiring re-wash
40008	FaultActive	uint16	0=No fault, 1=Fault active
40009	FaultCode	uint16	3001=Temp Low, 3002=Filter Clogged
40013	WashPressure	uint16	bar x10 (6.5 = 65)
40014	WashTemp	uint16	Celsius x10 (55.0 = 550)
40022	PowerKW	uint16	kW x100

Business Purpose

Station Specifications

OPC UA Node Structure

Nodes are organized under namespace index 1. Browse from ns=1;s=OP20-CNC

Node ID	Type	Description
ns=1;s=OP20-CNC.State	String	IDLE, RUNNING, FAULTED, BLOCKED, STARVED
ns=1;s=OP20-CNC.Step	String	IDLE, LOADING, PROCESSING, UNLOADING
ns=1;s=OP20-CNC.CurrentPart	String	Serial number of part being processed
ns=1;s=OP20-CNC.PartsProduced	Int32	Total parts completed
ns=1;s=OP20-CNC.PartsGood	Int32	Good parts count
ns=1;s=OP20-CNC.PartsBad	Int32	Scrap + rework count
ns=1;s=OP20-CNC.SpindleSpeed	Float	Current spindle RPM
ns=1;s=OP20-CNC.SpindleLoad	Float	Spindle load percentage
ns=1;s=OP20-CNC.FeedRate	Float	Current feed rate (mm/min)
ns=1;s=OP20-CNC.CoolantPressure	Float	Coolant pressure (bar)
ns=1;s=OP20-CNC.CoolantTemp	Float	Coolant temperature (Celsius)
ns=1;s=OP20-CNC.Vibration	Float	Vibration level (mm/s)
ns=1;s=OP20-CNC.Temperature	Float	Machine temperature (Celsius)
ns=1;s=OP20-CNC.Voltage	Float	Supply voltage (V)
ns=1;s=OP20-CNC.Current	Float	Current draw (A)
ns=1;s=OP20-CNC.Power	Float	Current power consumption (kW)
ns=1;s=OP20-CNC.PowerFactor	Float	Power factor
ns=1;s=OP20-CNC.EnergyKWH	Float	Cumulative energy (kWh)
ns=1;s=OP20-CNC.ToolID	String	Current tool identifier
ns=1;s=OP20-CNC.ToolName	String	Current tool name
ns=1;s=OP20-CNC.ToolLifeCount	Int32	Current tool usage count
ns=1;s=OP20-CNC.ToolLifeLimit	Int32	Tool life limit
ns=1;s=OP20-CNC.ToolLifeRemaining	Int32	Remaining tool life
ns=1;s=OP20-CNC.FaultActive	Boolean	True if fault is active
ns=1;s=OP20-CNC.FaultCode	String	E2001=Bore OOS, E2002=Tap Break
ns=1;s=OP20-CNC.FaultName	String	Fault description
ns=1;s=OP20-CNC.RunTimeSec	Float	Accumulated run time
ns=1;s=OP20-CNC.DownTimeSec	Float	Accumulated down time
ns=1;s=OP20-CNC.IdleTimeSec	Float	Accumulated idle time

Business Purpose

Station Specifications

OPC UA Node Structure

Nodes are organized under namespace index 1. Browse from ns=1;s=OP40-TEST. Test-specific sensors provide leak rate and pressure decay measurements.

Node ID	Type	Description
ns=1;s=OP40-TEST.State	String	Machine state
ns=1;s=OP40-TEST.Step	String	IDLE, LOADING, PROCESSING, UNLOADING
ns=1;s=OP40-TEST.CurrentPart	String	Part serial number under test
ns=1;s=OP40-TEST.PartsProduced	Int32	Total parts tested
ns=1;s=OP40-TEST.PartsGood	Int32	Parts passed leak test
ns=1;s=OP40-TEST.PartsBad	Int32	Parts failed leak test
ns=1;s=OP40-TEST.TestPressure	Float	Current test pressure (bar)
ns=1;s=OP40-TEST.LeakRate	Float	Measured leak rate (cc/min)
ns=1;s=OP40-TEST.PressureDecay	Float	Pressure drop during test (mbar)
ns=1;s=OP40-TEST.Temperature	Float	Machine temperature (Celsius)
ns=1;s=OP40-TEST.Voltage	Float	Supply voltage (V)
ns=1;s=OP40-TEST.Current	Float	Current draw (A)
ns=1;s=OP40-TEST.Power	Float	Current power consumption (kW)
ns=1;s=OP40-TEST.PowerFactor	Float	Power factor
ns=1;s=OP40-TEST.EnergyKWH	Float	Cumulative energy (kWh)
ns=1;s=OP40-TEST.FaultActive	Boolean	Fault status
ns=1;s=OP40-TEST.FaultCode	String	E4001=Air Pressure Low, E4002=Seal Wear
ns=1;s=OP40-TEST.FaultName	String	Fault description
ns=1;s=OP40-TEST.RunTimeSec	Float	Accumulated run time
ns=1;s=OP40-TEST.DownTimeSec	Float	Accumulated down time
ns=1;s=OP40-TEST.IdleTimeSec	Float	Accumulated idle time

Business Purpose

Available Endpoints

Master Data

Work Orders

Production Data

Quality & Downtime

Real-Time Status

Business Purpose

Available Endpoints

Inventory

Automation & Movements

Topic Structure

All topics use the format factory/LINE-BC-01/... where LINE-BC-01 is the production line ID.

To receive all events, subscribe to: factory/LINE-BC-01/#

Event Stream Topics

Aggregated event streams - subscribe to these for all events of a type

Topic	Event Type	Description
factory/LINE-BC-01/events/state_change	STATION_STATE_CHANGE	All station state transitions
factory/LINE-BC-01/events/cycle	CYCLE_START, CYCLE_COMPLETE	All cycle events from all stations
factory/LINE-BC-01/events/production	PART_COMPLETED	Parts finished (GOOD/SCRAP/REWORK)
factory/LINE-BC-01/events/faults	FAULT_TRIGGERED, FAULT_CLEARED	All fault events from all stations
factory/LINE-BC-01/events/work_orders	WORK_ORDER_STARTED, WORK_ORDER_COMPLETED	Work order lifecycle events

Equipment Topics (per station)

Station-specific events. Stations: OP10-CNC, OP20-CNC, OP30-WASH, OP40-TEST

Topic	Event Type	Description
factory/LINE-BC-01/equipment/{station}/state	STATION_STATE_CHANGE	State change (IDLE, RUNNING, FAULTED, etc.)
factory/LINE-BC-01/equipment/{station}/cycle/start	CYCLE_START	Part started processing at station
factory/LINE-BC-01/equipment/{station}/cycle/complete	CYCLE_COMPLETE	Part finished with measurements & process data
factory/LINE-BC-01/equipment/{station}/fault	FAULT_TRIGGERED	Fault occurred at station
factory/LINE-BC-01/equipment/{station}/fault/cleared	FAULT_CLEARED	Fault resolved at station

Parts & Work Orders Topics

Topic	Event Type	Description
factory/LINE-BC-01/parts/completed	PART_COMPLETED	Part finished all operations
factory/LINE-BC-01/work_orders/started	WORK_ORDER_STARTED	Work order started production
factory/LINE-BC-01/work_orders/completed	WORK_ORDER_COMPLETED	Work order finished

Quality & Alerts Topics

Topic	Event Type	Description
factory/LINE-BC-01/quality/defects	DEFECT_DETECTED	Quality defect with root cause
factory/LINE-BC-01/alerts/fault	FAULT_TRIGGERED	Critical fault alerts
factory/LINE-BC-01/simulation/profile	PROFILE_CHANGE	Simulation profile changed

Periodic Status Topics (every 5 seconds)

Topic	Event Type	Description
factory/LINE-BC-01/status/production	LINE_STATUS	Production line summary (counts, PPH)
factory/LINE-BC-01/status/equipment/{station}	EQUIPMENT_STATUS	Station state, counters, energy, faults
factory/LINE-BC-01/status/buffers/{buffer}	BUFFER_STATUS	Buffer level and capacity
factory/LINE-BC-01/status/work_order	WORK_ORDER_STATUS	Current work order progress

Stations: OP10-CNC, OP20-CNC, OP30-WASH, OP40-TEST
Buffers: buffer-raw, buffer-1, buffer-2, buffer-3, buffer-finished

Example Payloads

CYCLE_COMPLETE Event

{
  "event_type": "CYCLE_COMPLETE",
  "station_id": "OP10-CNC",
  "part_serial": "SN-000042",
  "cycle_time_sec": 52.3,
  "result": "GOOD",
  "tool_used": "T1-FACE-MILL",
  "tool_life_at": 245,
  "energy_kwh": 0.42,
  "measurements": [...],
  "process_data": {
    "spindle_speed_rpm": 3500,
    "spindle_load_percent": 45.2,
    "feed_rate_mm": 250
  },
  "timestamp": "2024-01-15T10:30:52Z"
}

FAULT_TRIGGERED Event

{
  "event_type": "FAULT_TRIGGERED",
  "station_id": "OP10-CNC",
  "fault_id": "FLT-12345",
  "fault_code": "E1001",
  "fault_name": "Spindle Overload",
  "description": "Spindle motor current exceeded threshold",
  "severity": "major",
  "start_time": "2024-01-15T10:25:30Z",
  "timestamp": "2024-01-15T10:25:30Z"
}

LINE_STATUS Event (Periodic)

{
  "event_type": "LINE_STATUS",
  "total_produced": 1250,
  "good_count": 1220,
  "scrap_count": 20,
  "rework_count": 10,
  "parts_per_hour": 42.5,
  "timestamp": "2024-01-15T10:35:00Z"
}

EQUIPMENT_STATUS Event (Periodic)

{
  "event_type": "EQUIPMENT_STATUS",
  "station_id": "OP10-CNC",
  "state": "RUNNING",
  "step": "PROCESSING",
  "current_part": "SN-000042",
  "parts_produced": 125,
  "parts_good": 120,
  "parts_bad": 5,
  "run_time_sec": 3600.5,
  "down_time_sec": 120.0,
  "idle_time_sec": 280.3,
  "fault_active": false,
  "power_kw": 8.5,
  "energy_kwh": 42.3,
  "timestamp": "2024-01-15T10:35:00Z"
}

BUFFER_STATUS Event (Periodic)

{
  "event_type": "BUFFER_STATUS",
  "buffer_id": "buffer-raw",
  "name": "Raw Material Buffer",
  "current_level": 85,
  "capacity": 100,
  "timestamp": "2024-01-15T10:35:00Z"
}

WORK_ORDER_STATUS Event (Periodic)

{
  "event_type": "WORK_ORDER_STATUS",
  "order_id": "WO-2024-001",
  "product_id": "BC-2024-A",
  "target_qty": 100,
  "produced_qty": 85,
  "good_qty": 82,
  "scrap_qty": 2,
  "rework_qty": 1,
  "status": "in_progress",
  "timestamp": "2024-01-15T10:35:00Z"
}

Quick Start

Test the MQTT broker with any MQTT client:

Using mosquitto_sub

# Subscribe to all factory events
mosquitto_sub -h localhost -p 1883 -t "factory/LINE-BC-01/#" -v

# Subscribe to fault events only
mosquitto_sub -h localhost -p 1883 -t "factory/LINE-BC-01/events/faults" -v

# Subscribe to specific station
mosquitto_sub -h localhost -p 1883 -t "factory/LINE-BC-01/equipment/OP10-CNC/#" -v

Using Node.js

const mqtt = require('mqtt');
const client = mqtt.connect('mqtt://localhost:1883');

client.on('connect', () => {
  client.subscribe('factory/LINE-BC-01/#');
});

client.on('message', (topic, message) => {
  const event = JSON.parse(message.toString());
  console.log(topic, event);
});

Connection Details

Parameter	Value
Host	localhost
Port	5432
Database	factory
Username	factory
Password	factory123

Database Schema

The factory database contains 15 tables organized into logical groups:

Organization & Personnel

Table	Description	Key Columns
departments	Factory departments	id, name, code, manager_id
employees	Employee records	id, employee_id, first_name, last_name, email, department_id, role, hire_date
shifts	Shift definitions	id, name, start_time, end_time, days_of_week
shift_assignments	Employee shift assignments	id, employee_id, shift_id, start_date, end_date
skills	Skills catalog	id, name, category, description
employee_skills	Employee certifications	employee_id, skill_id, proficiency_level, certified_date

Equipment & Maintenance

Table	Description	Key Columns
equipment	Factory equipment/machines	id, equipment_id, name, type, manufacturer, model, serial_number, station_id
maintenance_schedules	Planned maintenance	id, equipment_id, maintenance_type, frequency_days, last_performed, next_due
maintenance_records	Maintenance history	id, equipment_id, maintenance_type, performed_by, performed_at, notes, parts_replaced

Supply Chain

Table	Description	Key Columns
suppliers	Material suppliers	id, name, code, contact_name, email, phone, address, rating
materials	Raw materials inventory	id, material_id, name, category, unit, supplier_id, lead_time_days, min_stock
customers	Customer records	id, name, code, contact_name, email, phone, address

Products & Quality

Table	Description	Key Columns
products	Product catalog	id, product_id, name, description, customer_id, cycle_time_sec, weight_kg
bom_items	Bill of materials	id, product_id, material_id, quantity, unit
quality_specs	Quality specifications	id, product_id, parameter, min_value, max_value, unit, station_id

Sample Queries

List All Employees with Department

SELECT e.employee_id, e.first_name, e.last_name, e.role, d.name as department
FROM employees e
JOIN departments d ON e.department_id = d.id
ORDER BY d.name, e.last_name;

Current Shift Assignments

SELECT e.first_name, e.last_name, s.name as shift,
       s.start_time, s.end_time, sa.start_date
FROM shift_assignments sa
JOIN employees e ON sa.employee_id = e.id
JOIN shifts s ON sa.shift_id = s.id
WHERE sa.end_date IS NULL
ORDER BY s.name;

Equipment Maintenance Due

SELECT eq.equipment_id, eq.name, ms.maintenance_type,
       ms.next_due, ms.frequency_days
FROM maintenance_schedules ms
JOIN equipment eq ON ms.equipment_id = eq.id
WHERE ms.next_due <= CURRENT_DATE + INTERVAL '7 days'
ORDER BY ms.next_due;

Employee Skills Matrix

SELECT e.first_name, e.last_name, sk.name as skill,
       es.proficiency_level, es.certified_date
FROM employee_skills es
JOIN employees e ON es.employee_id = e.id
JOIN skills sk ON es.skill_id = sk.id
ORDER BY e.last_name, sk.category;

Product Bill of Materials

SELECT p.product_id, p.name as product, m.name as material,
       b.quantity, b.unit, s.name as supplier
FROM bom_items b
JOIN products p ON b.product_id = p.id
JOIN materials m ON b.material_id = m.id
JOIN suppliers s ON m.supplier_id = s.id
ORDER BY p.name, m.name;

Quick Start

Connect to the database using any PostgreSQL client:

Using psql

# Connect to the factory database
psql -h localhost -p 5432 -U factory -d factory

# List all tables
\dt

# Describe a table
\d employees

# Run a query
SELECT * FROM employees LIMIT 5;

Using Python

import psycopg2

conn = psycopg2.connect(
    host="localhost",
    port=5432,
    database="factory",
    user="factory",
    password="factory123"
)

cur = conn.cursor()
cur.execute("SELECT * FROM employees")
for row in cur.fetchall():
    print(row)

conn.close()

Using Node.js

const { Pool } = require('pg');

const pool = new Pool({
  host: 'localhost',
  port: 5432,
  database: 'factory',
  user: 'factory',
  password: 'factory123'
});

pool.query('SELECT * FROM employees', (err, res) => {
  console.log(res.rows);
  pool.end();
});