Real-time data in production: Why it is essential today

In digitized manufacturing, recording data in real time is becoming increasingly important. data that live come from machines, systems or processes not only enable transparency, but also create freedom of choice, quality and efficiency. In an MES environment such as gboMES, real-time data is the engine for smart, agile production processes.

What does “real-time data” mean in practice?

Real-time data is measurement, process, operating and machine data that is captured, processed and made visible promptly — ideally immediately. examples:

• Quantities, alarms, downtimes directly from the machine (machine data aquisition, MDA)
• Process parameters such as temperature, pressure, humidity (process data acquisition, PDA)
• Running times and utilization data of tools (tool management, TM)
• Staff hours and order times (personnel time and production data collection, PZBDE)

Why real-time data (MES) brings significant added value

Respond faster to discrepancies

If tolerances are exceeded or a system fails, countermeasures can be taken immediately instead of later through manual evaluation.

Reduce scrap and rework

By recording and displaying process parameters early on, errors can be identified before they have an effect.

Optimized machine and resource utilization

With real-time data, you can identify bottlenecks, adjust plans and improve utilization.

Increasing transparency

With dashboards and key figures (KPIs), everyone can see what the current status is — from the operator to management level.

Linking with ERP and other systems

Live actual data continues to flow automatically, e.g. for target/actual comparisons, planning, reporting.

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How GBomes uses & supports real-time data

We offer with gbo MES software that systematically integrates real-time data — from machine data aquisition (MDA) to process data aquisition (PDA) to operational data collection(ODC).

Some successful components:

• MDA connects machines, systems and lines with management and personnel, records quantities, faults and process values in real time.
• PDA provides insight into process data such as pressure, temperature or energy consumption, so that deviations are immediately visible.
• KPI modules and dashboards: Visualization of data live on the shop floor, on the go or via web dashboards. As a result, decisions are more well-founded and faster.

Challenges & what companies should pay attention to when it comes to real-time data

For real-time data to really add value, a few prerequisites must be met:

1. Data quality and integrity
   Missing sensors, unreliable data sources, or transmission delays can make live data useless.
2. Technical connection
   Machines, systems and tools must offer interfaces or be adapted. gboMES can also handle heterogeneous environments.
3. scalability
   Systems should be able to grow — from individual lines to the entire factory, including quality, tool and maintenance data.
4. User-friendly visualization
   Data is only useful if it is presented in an understandable form (dashboards, alerts, etc.).
5. Security & privacy
   Real-time data often includes sensitive information. Security, rights management and, if necessary, data storage are important.

conclusion

Real-time data is no longer a “nice to have” but a central component of efficient, agile production. With MES systems such as gboMES, data can be recorded and evaluated live and used for operational and strategic decisions. This improves quality, reduces costs and strengthens competitiveness — especially for SMEs.

If you want to know how your company can actually benefit from real-time data collection, or which data sources you should tap into now — talk to us.

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