There are factories around the world that operate for years without unplanned downtime. What makes them different, and how can we adapt the same principles in your factory?
Culture of discipline and preventive maintenance
In a truly 24/7 functional factory, preventive maintenance is not just a checklist — it is a disciplined practice supported by intelligent software – this is what the RAP Systems does. Real-time data acquisition and proactive alarm management provide instant visibility into equipment health and trigger timely actions. Historical data analysis brings context, uncovering performance trends that guide better decisions. By combining anomaly detection with advanced diagnostics, irregular patterns are identified early, and functional parameters can be assessed under exceptional conditions. Predictive operations then forecast equipment behaviour, allowing teams to act proactively and prevent costly disruptions before they happen.
As a practical demonstration of these principles, RAP Systems successfully implemented an automation solution in a chocolate factory in Europe. This project illustrates how preventive maintenance, supported by intelligent software, translated into measurable uptime gains and reduced unplanned downtime.
Digital twins and prediction
Digital twins go beyond static models. They simulate equipment in parallel with real operations, continuously fed by live data streams. This dynamic connection allows managers to anticipate failures before they occur and to test “what if” scenarios without risking production. By combining predictive operations with historical data analysis and anomaly detection, digital twins become a powerful tool for forecasting equipment behaviour, optimizing energy use, and ensuring process stability. Instead of reacting to breakdowns, factories can see disruptions coming and act in advance.
The completed project in the food industry shows how digital twins are not just theoretical. By modelling critical chocolate production lines in real time, RAP Systems enabled managers to anticipate equipment stress points, optimize energy consumption, and maintain consistent quality output.
Layered automation
It is no longer about PLC and SCADA alone. True resilience comes from connecting automation layers with MES and ERP systems, giving managers full visibility of processes, resources, and performance across the entire plant.
A critical enabler that RAP Systems puts into practice is seamless integration with existing systems: SCADA and PLC platforms such as Ignition, Siemens SIMATIC, or Rockwell FactoryTalk; enterprise software like SAP and Oracle for ERP and MES integration; and industrial protocols including OPC-UA, MQTT, Modbus, and HTTP.
This open interoperability removes vendor lock-in and ensures that new layers of automation — from edge devices to enterprise applications — communicate effortlessly. The result is a unified digital backbone where machine data flows smoothly from the shop floor to strategic decision-making.
Integration was also proven in practice. In the European chocolate factory, RAP Systems connected existing PLCs and SCADA with higher-level ERP systems, ensuring smooth communication across production, logistics, and inventory management. This layered automation approach directly supported 24/7 operational continuity.
Continuous training
Operators are not mere “button pushers.” In modern factories, they act as partners of the technology, empowered by training and supported by digital tools. Virtual assistants can guide them through complex decision-making workflows, while real-time dashboards and mobile alerts integrated by RAP Systems keep them informed about machine performance without constant manual checks.
Training programs focused on data interpretation and system interaction enable operators to respond quickly to anomalies, collaborate with predictive systems, and contribute actively to process stability and innovation. In a 24/7 environment, knowledge is as critical as machinery.
Beyond machines, RAP Systems emphasized workforce readiness during this project. Operators in the chocolate factory received training on interpreting predictive dashboards and responding to automated alerts, enabling them to collaborate effectively with digital tools and reinforce uninterrupted production.
RAP Systems advices – mini-checklist for your factory
- Introduce a predictive maintenance calendar, not just reactive fixes.
- Add vibration and temperature sensors for critical equipment.
- Start with a simple SCADA module to ensure 24/7 visibility.
- Train your operators — an uninterrupted factory is also the result of a well-prepared team.
This project stands as evidence that the 24/7 factory is achievable. RAP Systems’ automation solution not only reduced downtime but also enhanced product consistency, validated by the continuous output of premium chocolate products for international markets.
RAP Systems conclusion is that the factory that never stops is not a utopia. It is the result of a mix of technology, discipline, and vision. And every small step in this direction means less loss and greater competitiveness.
Silviu Cucuian: General Manager RAP Systems: silviu.cucuian@rap-group.ro
Ioana Lorenc: Business Development and Marketing Director RAP Group: Ioana.lorenc@rap-group.ro
