Diesel Engine Remanufacturing Software
Remanufacturing ERP for diesel engines. Core tracking, disassembly workflows, parts inspection, and rebuild scheduling in one integrated system.
Industry Solutions
Diesel Engine Remanufacturing
Production Intelligence for Engine Remanufacturers
From core receiving to dyno certification — manage every stage of diesel engine remanufacturing with OPC UA-connected workstations, iMQTT real-time telemetry, and agentic AI diagnostics that catch failures before they ship.
CAT C-SeriesCummins ISX/X15Detroit DD-SeriesVolvo D-SeriesPACCAR MX
Connected Remanufacturing Floor
OPC UA Station Integration
Every workstation, torque tool, and dyno cell streams live data via OPC UA — no manual entry, no blind spots.
iMQTT Real-Time Telemetry
Industrial MQTT broker pushes compression, oil pressure, RPM, and torque to your control room at 500ms intervals.
Agentic AI Diagnostics
AI agent analyzes dyno data, compression patterns, and wear signatures — flags defects and generates rework recommendations autonomously.
Dyno Cell Monitoring
Per-cylinder compression tracking, full-load break-in monitoring, and automated pass/fail certification against OEM specs.
Live Simulation
Production Control Room
What your remanufacturing floor looks like when every station is connected. Real-time dyno telemetry, AI-driven insights, and complete core pipeline visibility — all in one control room.
LIVE
DIESEL ENGINE REMANUFACTURING — PRODUCTION CONTROL ROOMOPC UA8/8 Connected
iMQTTActive
AI AgentOnline
06:31:09 PMOEE Score
84.2%
Target 88%
Units Today
32 / 36
Daily Target
First Pass Yield
91.4%
Rework 8.6%
Core Pipeline
147
Units in Process
Active Faults
1
7 AI Recs
Core Pipeline
23
Awaiting
6
Disassembly
4
Cleaning
9
Inspection
7
Machining
10
Assembly
3
Testing
5
Ship Ready
ST-01Disassembly Bay 1ACTIVE
J. Martinez
reman/st01/disassembly
Current Engine
CAT C15 SN#4MG-84721
CAT C-Series
Cylinder Head Removal
Cycle Time
42s
Target: 45s
Units
6/8
Completed
Coolant Temp
72°F
No Alerts
Injector cup wear pattern suggests early fuel dilution — flag for metallurgical review
ST-02Cleaning & PrepACTIVE
R. Okonkwo
reman/st02/cleaning
Current Engine
Cummins ISX15 SN#79038412
Cummins ISX
Hot Tank Alkaline Wash
Cycle Time
65s
Target: 60s
Units
4/6
Completed
Coolant Temp
185°F
Cycle time over target
Cycle time 8% above target — bath temperature trending low, recommend heater check
ST-03Precision MachiningACTIVE
D. Kowalski
reman/st03/machining
Current Engine
Detroit DD15 SN#06-112847
Detroit DD-Series
Cylinder Bore Honing
Cycle Time
38s
Target: 40s
Units
7/8
Completed
Coolant Temp
68°F
No Alerts
Bore geometry within spec — surface finish Ra 0.4 µm optimal for ring seating
ST-04Assembly Station AACTIVE
T. Williams
reman/st04/assembly
Current Engine
Volvo D13 SN#VE132985
Volvo D-Series
Piston & Ring Installation
Cycle Time
55s
Target: 55s
Units
5/7
Completed
Coolant Temp
70°F
No Alerts
Ring gap measurements nominal — torque sequence verified via OPC UA torque wrench
ST-05Assembly Station BINSPECTION
L. Nguyen
reman/st05/assembly
Current Engine
PACCAR MX-13 SN#MX-447821
PACCAR MX
Valve Train Assembly
Cycle Time
48s
Target: 50s
Units
5/7
Completed
Coolant Temp
69°F
No Alerts
Valve lash within OEM spec — AI vision inspection passed all 24 check points
ST-08Final QC & ShippingACTIVE
S. Patel
reman/st08/shipping
Current Engine
Detroit DD13 SN#06-098234
Detroit DD-Series
Final Documentation & Label
Cycle Time
22s
Target: 25s
Units
8/8
Completed
Coolant Temp
70°F
No Alerts
All warranty docs auto-generated — 8/8 units passed final inspection, on pace for daily target
MonitorZ Production Intelligence — Diesel Engine Remanufacturing Module v4.2Data refresh: 2.2s | OPC UA polling: 500ms | iMQTT QoS: 2
Integration Platform
OPC UA + iMQTT to Agentic AI
MonitorZ connects your remanufacturing equipment using industrial-grade OPC UA and iMQTT protocols, feeding a live data stream to an AI agent that monitors every engine, every station, every shift.
OPC UA Node Mapping — Torque tools, CMMs, dyno cells, and test benches mapped to OPC UA address space. All data standardized and timestamped.
iMQTT Broker QoS 2 — Industrial MQTT with quality-of-service level 2 guarantees every sensor reading reaches the platform — no dropped data.
Agentic AI Analysis — AI agent subscribes to all topics, correlates compression, thermal, and torque data, and autonomously generates actionable recommendations.
Automatic Escalation — When AI detects a critical anomaly, it creates a work order, alerts the supervisor, and logs it in the quality record — without human intervention.
// OPC UA → iMQTT → AI Agent
subscribe('reman/st07/dyno/compression')
↓ Cyl3: 440 psi — threshold 456 psi
ai_agent.analyze(payload)
↓ Pattern: valve seat failure signature
ai_agent.create_alert({
severity: "CRITICAL",
engine: "Cummins X15 #79214533",
action: "STOP TEST — Re-inspect Cyl 3"
})
✓ Work order created
✓ Supervisor notified via iMQTT push
✓ Quality record updated
Remanufacturing-Specific Features
Built by people who understand the difference between new manufacturing and remanufacturing
Core Management
Track cores from receiving inspection through every remanufacturing stage. Grade cores on arrival, manage core bank inventory, and maintain full chain-of-custody documentation.
Dynamometer Integration
Live dyno data ingestion via OPC UA. Per-cylinder compression trending, full-load test profiles, and automated pass/fail comparison against OEM factory specs.
AI-Powered Diagnostics
Agentic AI analyzes wear patterns, compression signatures, and thermal data to predict failures, recommend corrective actions, and learn from every engine processed.
Disassembly Inspection
Structured teardown inspection forms with photo capture, wear measurement recording, and automatic BOM generation for required replacement parts.
Warranty & Certification
Auto-generate remanufacturing certificates, warranty documentation, and full test reports. Every unit ships with a complete digital record of every operation performed.
Parts & Kit Management
Engine-family-specific rebuild kits, gasket sets, and bearing inventories. Auto-consume parts during assembly with full traceability to supplier lot and batch.
OEE & Throughput Analytics
Real-time OEE by station, first-pass yield trending, rework root cause analysis, and daily throughput against target — always visible on the control room screen.
Multi-Stage Work Orders
Route engines through disassembly, cleaning, inspection, machining, assembly, and dyno testing as a single work order. Every operation tracked, timed, and signed off.
OPC UA + iMQTT
Connected Equipment
Torque wrenches, CMMs, honing machines, hot tanks, and dyno cells all connected via OPC UA. iMQTT streams live sensor data to your AI agent and control room continuously.
Why Reman Shops Choose MonitorZ
The Operational Challenges We Solve
Diesel engine remanufacturing has complexity that generic ERP systems simply weren't designed for. Here's where operators lose time — and how we fix it.
Pain Point
Paper-Based Dyno Data Collection
The Problem
Techs hand-write compression readings, then transcribe them to spreadsheets hours later. Defects slip through. OEM spec comparisons happen after the fact — if at all.
MonitorZ Solution
OPC UA streams every dyno reading live. AI compares against OEM specs in real time and flags issues before the engine leaves the cell.
Pain Point
No Visibility Into Core Pipeline
The Problem
Shops can't answer "how many cores are in cleaning right now?" without physically walking the floor. Cores sit idle, throughput stalls, and customer commitments get missed.
MonitorZ Solution
Core bank tracking with real-time stage visibility — receiving, grading, cleaning, machining, assembly, dyno, and shipping — in one control room view.
Pain Point
Rework Identified Too Late
The Problem
Defects found at final dyno test mean the engine gets torn back down — after full assembly labor has been invested. Average rework adds 6–12 hours per unit.
MonitorZ Solution
Agentic AI analyzes wear signatures and compression patterns at the inspection stage, catching failures before assembly begins.
Pain Point
Warranty Documentation Done Manually
The Problem
Warranty certs and test reports are assembled from multiple spreadsheets after the fact — prone to gaps, errors, and customer disputes that are hard to defend.
MonitorZ Solution
Every operation, torque spec, test reading, and tech sign-off is captured automatically. Warranty cert and full test report generate at certification — zero assembly.
Become a Reference Customer
We're actively implementing with diesel remanufacturers now. Early adopters get white-glove onboarding, direct engineering access, and preferred pricing — plus the chance to shape the roadmap.
Supported Engine Families
Caterpillar
C7, C9, C10, C12, C13, C15, C18, 3306, 3406
Cummins
ISB, ISC, ISL, ISM, ISX, X12, X15, QSK
Detroit Diesel
Series 60, DD13, DD15, DD16, MBE4000
Volvo
D11, D13, D16, VED12, VED7
PACCAR
MX-11, MX-13, PX-6, PX-7, PX-8, PX-9
International / Navistar
MaxxForce 7/9/10/11/13, A26
Mercedes-Benz / OM
OM906, OM926, OM457
Mack / Volvo
MP7, MP8, MP10, E7, E-Tech
Connect Your Remanufacturing Floor
See how MonitorZ OPC UA integration, iMQTT telemetry, and agentic AI transform diesel engine remanufacturing operations — from core receiving through dyno certification.