Efficient machine data collection for your company

Efficient machine data collection for your company

Michael Möller
Michael Möller
9 mins
January 11, 2024
January 11, 2024

Optimize your manufacturing processes with precise machine data collection and increase efficiency in real time.

At the heart of the modern manufacturing industry and in the course of ongoing development towards Industry 4.0, machine data collection (MDE) plays a decisive role. The ability to monitor and optimize production processes is fundamentally based on collecting data and then analyzing it. gBOmes, an advanced MES system, is regarded as an efficient solution that not only offers you great added value in production optimization, but also enables real-time data collection. Learn how you can make your production processes more efficient by using MDE.

The relevance of machine data collection in the age of Industry 4.0

In the advancing era of Industry 4.0, machine data collection (MDE) is a core component of modern production. It acts as a catalyst for digital transformation from manufacturing companies by providing crucial data for smart factory concepts and significantly driving forward both automation and networking of production systems.

Integration with smart factory concepts

Embedding MDE in smart factory structures enables seamless and intelligent processing of production data. This creates a basis for adaptive and self-optimizing manufacturing systems that are able to react to changes in real time and increase production efficiency.

Automation and connectivity in production

The implementation of MDE opens the door to a new era of production technology. The automation of processes and data monitoring are optimized and contribute to the seamless exchange of information within networked production systems. MDE is therefore an essential driver for networking industrial production facilities and enables a future-proof orientation in international competition.

With the introduction of machine data collection, you are entering the next level of industrial manufacturing, where optimized process control and efficient data management have become a reality.

Machine data collection and its significance for data analysis and processing

Data collection is a critical step in ensuring efficient production processes. In Industry 4.0, the data analysis and data processing production-related actual data is becoming increasingly relevant, as it has a profound influence on the performance of production lines.

Machine data collection (MDE) is the process of collecting, storing, and processing data generated during the manufacturing process. This data is crucial for evaluating production efficiency and machine condition. The integration of MDE within production data collection (BDE) provides additional insights into the material flow and the status of production orders.

The use of cutting-edge technologies for retrofit measures, such as OPC architectures and microcontroller controls, results in ultra-modern and efficient machine data collection. Such systems make it possible to update existing machines with new sensors and software so that they are able to provide valuable data for production monitoring and optimization.

  • Data analysis: In-depth analysis of the information collected to uncover bottlenecks and identify potential for improvement.
  • Data processing: Transformation of raw data into meaningful information that can be used for operational decision-making processes.
  • Production-related actual data: Real-time monitoring and documentation of the production process to enable seamless quality assurance and process control.

It is obvious that advanced machine data collection is a central pillar for companies that want to optimize their production processes in the era of Industry 4.0. The correct collection and analysis of machine data gives companies decisive insights and the ability to achieve comprehensive transparency of their processes.

Planning steps for implementing an MDE system

The introduction of an MDE system is an essential step for modern production environments that requires careful planning and strategy. Before you dive deep into the MDE project, preparation is the key to success. It is about setting the right course to ensure smooth implementation and commissioning of the system.

Importance of thorough preparation

Comprehensive preparation includes identifying the machines involved, defining the types of data to be collected, and understanding the specific requirements of your production environment. The precise definition of your objectives for the MDE project is a decisive step that forms the basis for all further decisions. Check how well your existing infrastructure is prepared for implementation and whether the planned data collection is feasible.

From selection to start-up

Careful planning is followed by the selection and procurement of the appropriate hardware and software. Prioritize sensors and devices that can be seamlessly integrated into your environment and ensure that the data collected provides a clear picture of operations. Selecting a suitable software solution also requires attention, as it is crucial for processing and analyzing your data. After installation, the start-up of the system is a significant moment when all components come together and prove their performance.

  • Identification of machines and data for the MDE project
  • Clarifying the objectives and reviewing the infrastructure for feasibility
  • Procurement and installation of compatible sensors and devices
  • Select and set up a software solution that meets your data needs
  • Test runs and adjustments before final commissioning

At every stage of the process, it's critical to let your implementation strategy be guided by your organization's needs and goals. The investment in thorough preparation and thoughtful selection will pay off when your MDE system is up and running.

Difference between production and machine data

When evaluating and analyzing manufacturing processes, there is a precise distinction between production data and Machine data plays a central role. Production data directly reflect measurable results of the production process, such as the number of units manufactured or the quality of the end products. When generating this data, the focus is on efficiency and productivity of the entire manufacturing process.

In contrast, machine data refers to information relating to the performance and condition of the machines involved. This data, such as operating temperatures, power expenditure or energy consumption, is essential to evaluate the technical condition and performance of individual systems.

The synergy of production and Machine data enables full control and optimization of industrial manufacturing processes. It is important to keep an eye on both the quantity and quality of the goods produced as well as the efficiency and maintenance of the machines in order to ensure successful production processes in the long term.

Production data:

  • Production quantities (quantities)
  • Operating times of production plants
  • Quality data of the end products

Machine data:

  • Machine states (e.g. temperature, pressure)
  • Machine energy consumption
  • maintenance intervals

The integration of both types of data into operational management enables you to make well-founded decisions and continuously improve both production processes and maintenance strategies.

Technical options for data collection

Today's production landscape offers a variety of technological ways to collect data. From Use of sensors up to automated data generation There are various options available that are characterized by flexibility and efficiency. We look at the various approaches and their significance for Industry 4.0.

Modern use of sensors and APIs

The use of cutting-edge sensors opens up various opportunities for companies to record critical and relevant machine data in real time. These sensors measure important physical properties such as temperature, pressure, and vibration, which enables continuous monitoring of machine status. The integration of APIs (Application Programming Interfaces) also plays an important role by ensuring the smooth flow of data between machine control systems and higher-level systems.

From manual entry to automated data generation

While many companies rely on advanced technologies, the manual data collection exist in specific scenarios. It serves as a cost-effective alternative or addition when machines are not network-compatible or when specific information is required that cannot be collected by sensors. In parallel, the automated data generation gained in importance through the use of image processing systems and automatic logging, which ensures almost complete data recording.

OEE optimization through efficient use of data

In order to survive in a highly competitive production environment, continuous improvement of processes and machine performance is essential. OEE optimization is a key process here. Through the use of Real-Time Monitoring and precise Performance analyses Can you not only the Overall equipment effectiveness increase your production units, but also tap into significant savings potential.

Analyses to improve performance

With the help of well-founded data analyses, influencing factors can be identified that impair your machine performance. Through targeted OEE optimization based on the knowledge gained, you can reduce downtime and increase production speed. This creates room for growth and can sustainably promote profitability.

Improving overall equipment effectiveness

Overall equipment effectiveness is a key indicator in the manufacturing industry. Optimizing this value increases productivity and reduces costs. Through detailed performance analyses, weak points are revealed and targeted improvement measures are therefore initiated. Real-time monitoring enables you to react proactively to changes and continuously optimize your production processes.

Category: Definition -> Objective

  • availability: Length of time in which the plant is productive -> Maximizing productive time
  • ‍‍Power efficiency: Relation of actual output to theoretically possible output -> Optimum use of machine capacity
  • Quality rate: Share of defect-free products in total production -> increase in product quality

Empower yourself to master your production processes and increase your competitiveness by using OEE optimization as a strategic tool for your Overall equipment effectiveness use.

Machine data as a basis for predictive maintenance

The efficient use of machine data is revolutionizing predictive maintenance. By intelligently analyzing this data, you ensure a proactive upkeepthat the Machine condition continuously monitored to prevent impending failures. This allows downtimes to be minimized and the longevity of the systems to be maximized.

By collecting and evaluating performance data in real time, you can identify abnormalities and behavioral patterns early on that could indicate potential defects. This enables you to plan maintenance measures in a targeted and proactive manner instead of reacting to failures and faults.

  • Historical data evaluation: The analysis of past data helps to predict future maintenance work more precisely.
  • Real-time monitoring: Continuous monitoring of machine status allows quick and well-founded decisions to be made.
  • Optimize maintenance: Plan maintenance based on current data and not on a fixed, potentially inefficient schedule.

Integrating predictive maintenance into your maintenance operation is an important step towards advanced and efficient production. For this, the seamless merging of data in the sense of Industry 4.0 is a must. Decide to protect everyday operations from downtime through predictive maintenance while increasing effectiveness and profitability.

Benefits of real-time data collection for operational decisions

Real-time data collection is a key technology for dynamic and competitive production environments. It enables companies to react quickly to changes and make well-founded operational decisions. Find out here how collecting data in real time increases process reliability and ensures greater transparency in production.

Reaction speed and process reliability

By Real time data collection companies can react immediately to deviations in the production process and thus increase their response speed. This not only promotes process reliability, but also the flexibility with which fluctuations in the production process can be handled. The following table shows an example of how real-time monitoring supports operational decisions and ensures process reliability:

Area: Use of real-time data -> Impact on operational decisions

  • Production monitoring: Live tracking of machine performance and utilization -> Faster adjustment of production plans
  • Quality control: Recording of test results in real time -> Immediate measures in case of quality deviations
  • maintenance: Anomaly detection through continuous condition monitoring -> Targeted preventive maintenance

transparency in the production process

Another advantage of transparency Real-time data collection means improving the entire production process. Transparency not only supports the planning of maintenance intervals, but also helps to identify bottlenecks and optimize resource utilization efficiency. An improved overview makes it possible to make operational decisions in a data-based and timely manner. With this transparency, companies can strengthen their competitiveness and meet customer requirements more precisely.

Integration of MDE into existing ERP and MES systems

The seamless integration From machine data capture (MDE) to existing ERP and MES systems plays a key role in effective data management and strengthening the performance of production companies. The direct injection of machine data into these systems enables improved communication and collaboration across departments, which in turn leads to more efficient production planning and control.

The focus is in particular on the timely and precise recording of operating data and their rapid availability. This helps companies to react quickly and effectively to dynamic market conditions and manufacturing processes and thus create the basis for an agile and adaptive production environment.

The efficient integration It also requires comprehensive coordination between the relevant departments, which not only improves communication but also significantly increases data quality. Investments in the right infrastructure and appropriate interfaces guarantee that both the ERP and MES systems can seamlessly process the data delivered by the MDE system. The result is a harmonized data landscape that enables well-founded business decisions and more efficient production management.

Roles of BDE and MDE within production management

In the area of production management Both production data collection (BDE) and machine data collection (MDE) play important roles. BDE provides a comprehensive view of operational processes and is responsible for recording all relevant information resulting from operational operations, including both order and personnel data. MDE, on the other hand, focuses on providing machine-related information that is essential for maintaining and optimizing manufacturing processes.

Order monitoring is significantly simplified by using both systems, as a transparent overview of the current production status is possible. This makes it possible to react quickly to changes and potential disruptions and ensures that production always runs efficiently and smoothly.

Responsibility: Operational Data Collection (BDE) - Machine Data Collection (MDE)

  • Monitoring focus: Overall operational processes - machine-specific processes
  • Data collected: Order data, personnel data - production data, machine status
  • Objective: Optimizing operational processes — increasing machine efficiency
  • Impact on productivity: Improved planning and resource management — minimizing downtime and quality assurance

This complementary use of BDE and MDE enables seamless documentation and control of the production process, which forms the basis for continuous improvement and sustainable increase in success.

Summary of potential benefits of MDE

The efficiency and productivity gains that can be achieved through machine data collection (MDE) in modern production are significant. MDE enables companies to precisely monitor processes and optimize them promptly through transparent and seamless data collection. Especially in the context of Industry 4.0, this technology opens the doors to an automated and digitized production environment in which incidents can be minimized and resources can be used ideally.

The implementation of MDE systems allows an in-depth analysis of the machine status and production processes. In addition, the potential benefits of MDE are much more comprehensive: They range from improved process reliability to the basis for predictive maintenance. The continuous analysis and use of the collected data helps companies to continuously improve manufacturing processes and thus secure a decisive competitive advantage.

Ultimately, the successful integration of MDE into operational processes reflects the visionary power of a company. The goal of creating a state-of-the-art and networked production facility is becoming tangible and represents an enormous step towards a future-proof and intelligent factory. For manufacturing companies, it means that they are able to react quickly to market changes and to consolidate and expand their position in a dynamic sector of the economy.

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