Call: (502) 895-1895

 1701 Cargo Ct,           Louisville, KY 40299

Call: (502) 895-1895
1701 Cargo Ct, Louisville, KY 40299

Live PLC Cycle Step Monitoring, Built for Your Plant

When a machine stops mid-cycle, the hardest question is usually the simplest one: which step did it fail on? Wilson Controls' PLC Cycle Step Monitor answers that in real time. It watches each machine's cycle step-by-step over EtherNet/IP, flags any skipped or out-of-order step the instant it happens, and trends how long every step takes — all from one lightweight, on-premises service. Your production data never leaves your plant.

How it works

The monitor connects to your PLC over EtherNet/IP and reads the live step of each machine's cycle as it runs. You define the expected sequence — Home, Clamp, Load, Process, Eject, Verify, and so on — and the system compares what's actually happening against it. The moment a step is skipped, runs out of order, or stalls, it's caught and marked: OK, Skip, Out-of-order, Not-in-sequence, or Unknown. Instead of digging through PLC logic after the fact, your team sees exactly where the cycle broke, live.

What you can see

The current step of every monitored machine, updating in real time
Instant flags for skipped, out-of-order, or stalled steps
Per-step duration trends (average milliseconds per step) so your slowest step is obvious
90 days of cycle history for troubleshooting and continuous improvement
Multiple machines on a single dashboard

Why manufacturers use it

Find faults faster. When a machine faults, you already know which step it stopped on — no guessing, no tracing wires. Cut downtime and scrap. Catching an out-of-order or stalled step immediately means shorter stoppages and fewer bad parts moving downstream. Optimize cycle time. Per-step timing shows exactly where your bottleneck is, so improvement effort goes where it pays off. Prove what happened. Ninety days of step history gives you a clean record for quality reviews, warranty questions, and root-cause analysis.

Works with your existing equipment

The Cycle Step Monitor communicates over EtherNet/IP, so it works with your existing Allen-Bradley / Rockwell ControlLogix and CompactLogix controllers and other EtherNet/IP-capable PLCs — no rip-and-replace, no new hardware to design around. Wilson Controls handles the step definitions, integration, and installation for you. [CONFIRM PLC brands/protocols you support]

Where it's used

Manufacturers rely on cycle step monitoring on assembly stations, presses, palletizers, and packaging lines across automotive, food & beverage, distillery, and general manufacturing plants throughout the U.S. Anywhere a machine runs a repeatable sequence, step monitoring makes stoppages shorter and quality more consistent.

Get a cycle step monitor for your plant

Wilson Controls designs, builds, and installs each system to fit your machines and your process. Based in Louisville, KY with 35+ years of controls and automation experience, we deliver it end to end — from step definitions to install to support. Call (502) 895-1895 or contact us for a custom quote on PLC cycle step monitoring.

  PLC Cycle Step Monitor — FAQ

  Who sells a PLC cycle step monitor?
  Wilson Controls designs, builds, and installs PLC cycle step
  monitoring systems for manufacturers. Based in Louisville, KY, we
  deliver custom on-prem monitoring over EtherNet/IP for automotive,
  food & beverage, and general manufacturing plants.

  What is a PLC cycle step monitor?
  It is a system that watches each machine's cycle step live,
  flags skipped or out-of-order steps the instant they happen, and
  trends cycle time per step — all from one lightweight on-prem service.

  How do I get a PLC cycle step monitor for my plant?
  Contact Wilson Controls in Louisville, KY for a custom quote.