Downtime on a roll forming line can be costly — every hour lost in production can mean thousands in lost revenue. From PLC errors to mechanical issues or simple operator mistakes, roll forming machines require fast, expert attention to stay running efficiently.

At Machine Matcher, we understand these challenges, which is why we’ve developed a Remote Support & Subscription service. This service allows you to access expert guidance, troubleshooting, and machine monitoring — anywhere in the world — without waiting for an engineer to travel onsite.

Why Remote Support is Critical for Roll Forming Machines

Roll forming machines are highly precise systems, and even small errors can lead to misaligned profiles, paint defects, or production delays. Common issues include:

• Mechanical faults: roller misalignment, gearbox or chain issues

• Electrical/PLC faults: control errors, sensor failures, HMI problems

• Operator/setup mistakes: incorrect coil loading, wrong gauge, or tension issues

Traditional support often requires an engineer visit, which can be expensive and slow, especially for global operations. Remote support solves these problems by allowing our engineers to:

• Diagnose issues via photos, videos, or live PLC access

• Provide step-by-step guidance to operators

• Reduce unnecessary travel costs

• Solve problems faster, minimizing downtime

How Remote Support Works

Our Remote Support service is structured to be fast, secure, and easy to use. Here’s the step-by-step process:

1. Issue Submission
You submit the problem through our portal or by email, including:

• Machine model and serial number

• Operator details

• Description of the issue

• Photos, videos, or PLC logs

2. Remote Diagnosis
Our engineers analyze the information and determine the cause. This can often resolve issues remotely without any onsite visit.

3. Next Steps
We identify whether the problem is:

• A machine fault

• A setup issue

• Operator error

Based on this, we either provide guidance to correct it or schedule an engineer visit if necessary.

4. Resolution & Support
You receive solutions, detailed instructions, or a remote PLC adjustment. If onsite intervention is required, our team coordinates the visit efficiently.

Technical Requirements:

• PLC/HMI software compatible with the machine brand

• Secure VPN or industrial gateway (e.g., eWON Flexy, HMS Anybus)

• Stable internet connection at the machine site

• Video communication tools for live guidance

Security & Compliance:

• Two-factor authentication

• IP-restricted access

• Audit logs of all remote sessions

Pricing & Subscription Options

Our service is designed to be flexible and scalable, offering predictable costs and global support:

Ad-Hoc Troubleshooting: $100–$200 per session for one-off issues outside subscriptions.

Optional Annual Contracts: Ideal for multi-machine operations, bundling remote support with periodic preventive maintenance.

Benefits of a Remote Support Subscription

1. Faster Resolution – Many issues are fixed without waiting for an engineer.

2. Reduced Costs – Minimize expensive travel and emergency repairs.

3. Global Coverage – Support multiple machines worldwide with a centralized team.

4. Operator Education – Step-by-step guidance teaches operators to avoid repeat issues.

5. Predictable Budgeting – Fixed monthly fees allow better planning for maintenance costs.

6. Data Insights – Track common issues to improve training and support resources.

How We Can Set It Up for You

1. Onsite Assessment – Our team evaluates your machines and network connectivity.

2. Hardware Installation – We install industrial gateways or configure VPNs for secure access.

3. Engineer & Operator Training – We ensure both sides can safely and efficiently manage remote sessions.

4. Portal Integration – Track tickets, session history, and resources in one platform.

5. Optional Preventive Maintenance Scheduling – Combine remote support with scheduled checks to prevent future issues.

Real-World Examples

• Scenario 1: Operator error caused a profile misalignment. Resolved remotely via video guidance and PLC adjustment in under an hour.

• Scenario 2: PLC parameter error detected; engineers corrected it without traveling, saving the customer thousands in downtime and travel costs.

• Scenario 3: Proactive check identified a misaligned roller before production started, preventing potential damage to material and machine.

Conclusion & Call to Action

Remote Support subscriptions from Machine Matcher provide fast, expert, and global solutions for your roll forming machines. Whether it’s diagnosing errors, adjusting PLCs, or providing operator guidance, our service reduces downtime, cuts costs, and improves operational efficiency.

Get started today — let us set up secure remote access to your machines and protect your production lines with a subscription tailored to your needs.