Live SPC from the plant floor
See quality problems on your lines while the shift is still running.
SCADA Lean is a small industrial computer we install at your plant. It reads the PLCs you already have and sends the data securely to LSSI STATS, so your team gets live control charts, capability and alerts. No large automation project, no open ports, and the machines keep running exactly as they do today.
Line 2 · press-01
Bore diameter, mm · I-chart
Last
12.0233
Cpk (window)
0.82
Subgroups
42
Rule 1 · point above UCL
press-01 bore diameter is drifting. Quality lead notified, still inside spec.
01How it works
Your machines, one small device at the plant, and results your team opens in a browser
The node reads your PLCs, keeps a local copy of every reading, and sends them over an encrypted outbound connection. If the internet drops, nothing is lost.
Online · every reading reaches STATS Cloud within seconds
1 · Already at your plant
Machines and PLCs
The controllers that already run your lines, plus gauges and sensors. We only read from them.
2 · We install
SCADA Lean node
A fanless industrial computer in your cabinet. It collects the data and holds it safely if the internet drops.
3 · We operate
STATS Cloud
Stores every measurement and runs the statistics: control charts, capability, Gage R&R, AI explanations.
4 · Your people
Quality and CI teams
Live charts and reports in a browser, from the office, the floor or a phone. Alerts reach the right person.
02What changes
Quality decisions move from the weekly report to the moment the process drifts
01
Catch drift early
Alerts fire when a process starts to shift, before parts fall out of specification.
02
Capability you can trust
Cpk calculated from every part produced, not from a small manual sample.
03
Find where variation comes from
Compare lines, shifts, crews, materials and products side by side.
04
Prove each improvement
Before-and-after results tied to each improvement project, ready for management review.
03The package
Hardware, cloud and our team, in one subscription
Everything needed to go from PLC tags to live statistics. You don't buy servers, licenses or an integrator project.
On your floor
SCADA Lean node
- Fanless industrial PC, configured before it ships
- Edge software with drivers for your PLCs
- Local buffering if the internet drops
- Line display that keeps working offline
In the cloud
STATS Cloud
- Live control charts with out-of-control rules
- Cp/Cpk by line, shift and product
- Alerts to the people responsible
- AI interpretation and improvement projects
From our team
Deployment and support
- Site survey and network review with your IT team
- Commissioning and tag mapping
- Remote health monitoring and software updates
- Training for quality and CI engineers
Reference hardware
Built for the control cabinet, with a separate port for each network
- Standard model
- OnLogic Helix 320, fanless industrial PC
- Processor and memory
- Intel N250 (4 cores), 16 GB RAM
- Storage
- Industrial M.2 SSD, sized for several days of local buffering
- Network
- 4× 2.5 GbE: OT, uplink, optional second OT segment, service
- Security hardware
- TPM 2.0 onboard
- Power
- 12–36 V DC terminal block, works with standard 24 V cabinet supplies
- Mounting
- DIN rail, wall or VESA. Fanless, 0–50 °C
- Options
- 4G/5G modem for sites without an uplink. Rugged Karbon series for harsh environments
Final model and configuration are confirmed during the site survey.
PLC protocols
- OPC UASupported
- Modbus TCPSupported
- EtherNet/IP · Allen-BradleyNext
- Siemens S7Next
04For IT and OT security
Plant data reaches the cloud without opening your network
The design follows IEC 62443 zone-and-conduit principles. The node only opens connections outward, never forwards traffic between its ports, and never writes to a PLC.
0
inbound firewall rules or open ports
2
outbound connections: HTTPS 443 and Tailscale
R/O
read-only access to PLCs: no writes, no logic changes
Red: plant data to STATS Cloud. Blue dashed: the support tunnel, limited to the node itself.
- PLC access
- Read-only. It reads tags and registers and never writes values, downloads logic or changes setpoints.
- Network separation
- Two physical ports, one on the OT network and one uplink. IP forwarding is disabled, so the node cannot act as a bridge.
- Connection direction
- Outbound only: HTTPS on 443 to STATS, plus a Tailscale tunnel for support. No inbound rules or port forwarding.
- Remote support
- A WireGuard tunnel the node starts. Only named LSSI support staff, with SSO and MFA, limited to the node itself. Your IT team can require approval or switch it off.
- Encryption
- TLS 1.2 or later on every connection that leaves the plant.
- Identity
- Each node has its own credential, and a lost node can be revoked from the console. Users sign in to STATS with passkeys.
- Outages
- Data is buffered on the node while the uplink is down and sent once it returns, in order, without duplicates.
- Your data
- Your production data belongs to you. Retention, export and deletion terms are set in the agreement.
05Deployment
Six steps from a site survey to the first capability study, mostly handled by our team
- 1
Step 1
Site survey
We review your PLC models, network layout and the characteristics that matter most to quality, with your IT team.
- 2
Step 2
Node preparation
We load the site settings and drivers for your equipment before the node ships.
- 3
Step 3
Install and connect
Your technician mounts the node and plugs in two network cables. It calls home and shows as healthy.
- 4
Step 4
Tag mapping
Each PLC tag is linked to a characteristic, with its units and specification limits.
- 5
Step 5
Live monitoring
Control charts update with each subgroup, and rule violations notify the right people.
- 6
Step 6
First capability readout
Cp/Cpk by line and shift, with an improvement project opened on the largest gap.
LSSI STATS provides
- SCADA Lean node, configured
- Edge software, drivers and updates
- STATS Cloud workspace and user access
- Commissioning, tag mapping and training
- Remote health monitoring
Your plant provides
- A network port on the OT network and an uplink
- Outbound firewall rules for 443 and Tailscale
- Read access to the PLC tags in scope
- Specification limits for each characteristic
- A named IT/OT contact and a quality owner
06Plans
One annual subscription, sized by the number of PLCs you connect
Gauges and instruments connect at no extra charge. Only PLCs and controllers count toward the plan, plus a one-time setup per site.
Included in every plan
- SCADA Lean devices, replaced if one fails
- Software updates, data storage, alerts and remote support
- Gauges and instruments connect at no extra charge. Only PLCs count toward the plan
- Up to 50 monitored characteristics per PLC, pooled across your plan
Other options either connect to the machines or analyze the data. Few do both.
| Option | Live machine data | Live SPC and alerts | Capability studies | Screen at the line | Setup |
|---|---|---|---|---|---|
| Desktop statistics + spreadsheets | No | No | Yes | No | Data copied by hand |
| Traditional SCADA | Yes | Add-on | No | Yes | Integrator project |
| Machine-monitoring / OEE tools | Partial | No | No | Yes | Kit on each machine |
| SCADA Lean + STATS | Yes | Yes | Yes | Yes | Done by our team |
07FAQ
Questions plants ask us first
Can SCADA Lean change anything on my machines?
No. The edge software only reads tags and registers. It has no code path that writes values, downloads logic or changes setpoints, and the machines keep running exactly as they do today.
Does my IT team need to open a port?
No. The node opens two connections outward: HTTPS on port 443 to STATS Cloud, and a Tailscale tunnel our support team uses to maintain the node. No inbound firewall rule or port forwarding is needed.
What happens if the internet goes down?
The node keeps reading and stores every measurement locally. When the uplink returns, it sends the backlog in order. The cloud ignores anything it has already received, so nothing is lost or counted twice.
Which PLCs do you support?
OPC UA and Modbus TCP today, which covers most modern controllers and many gateways. EtherNet/IP (Allen-Bradley) and Siemens S7 drivers are next. Tell us your models and we confirm during the site survey.
Do we need to replace our SCADA or historian?
No. SCADA Lean runs alongside what you have. It reads the same tags and adds live statistics and capability on top; it is not a replacement for your HMI.
How is it priced?
One annual subscription, sized by the number of PLCs you connect. It includes the devices, software, storage, alerts and support, plus a one-time setup per site. Gauges and instruments do not count toward the plan.
Who owns the data?
You do. Retention, export and deletion terms are written into the agreement.
How do we start?
With one line and success measures we agree on before the start. A one-hour working session with your operations, quality and IT leads is enough to plan the site survey.
Proposed starting point
Start with one line.
We agree the success measures together before the start. Bring a rough count of PLCs, the characteristics that matter most to quality, and an IT contact. A one-hour working session is enough to plan the site survey.
Request a pilot