MPDV: Increased transparency and efficiency using machine data with HYDRA by MPDV

Machine Data Collection with HYDRA MDE

Application & benefits
Transparency and efficiency in any type of machine park!
In order to perfectly utilize available machines, manufacturing companies need to know how machines are currently used, as well as what potential can still be tapped from them. For this purpose, data must be systematically recorded and evaluated. A state-of-the-art machine data collection system, integrated in a Manufacturing Execution System (MES), offers the necessary range of functions to accomplish this.
Your Benefits
No more unreliable and time-consuming written documentation
Full transparency to current machine conditions
Improvement of maintenance processes based on reliable, actual data
Optimization of machine utilization by reducing downtimes and malfunctions
Longer machine utilization times and support for investment decisions
Machine data collection with HYDRA MDE
Both studies, and the experience from numerous projects, show that the average machine utilization is usually less than 60 percent. Unplanned downtimes have the lion’s share when it comes to wasting machine time with 10 to 15 percent. You can significantly increase machine efficiency by having reliable historical data on the machine behavior and thus you will have the background of all of its failures and malfunctions.
In addition to the order-related shop floor data collection, HYDRA MDE evaluates real time machine data recorded on the shop floor (e. g. machine status and quantities). Based on this, important KPI’s such as OEE (Overall Equipment Effectiveness) are calculated and then displayed in meaningful diagrams. From the collected data, you can find out everything you need to know about your machines, which is the first step in significantly increasing the availability and usage of your machines and systems. Combining this with a maintenance strategy (predictive maintenance), based on machine data, will result in higher productivity.
Furthermore, machine data enables reactive detailed planning on the shop floor, as well as forming a reliable basis for calculating premium and incentive wages.
Within HYDRA, MPDV offers the perfect supplement to the classic machine data collection when it comes to recording and evaluating energy consumption (HYDRA EMG) and process data (HYDRA PDV).
Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.
Highlights
Collect, evaluate and visualize data
You can cover all of the manufacturing processes with HYDRA MDE, from the collection to the visualization of machine data, using just one system. The evaluation of historical data reveals weak points in production and determines KPIs (e. g., OEE, efficiency) for production management and controlling.
In order to create the necessary transparency, the collected data must be up-to-date and reliable. For this purpose, HYDRA MDE offers a wide range of functions, including a mobile MES application.
Highlights of this solution are:
Automatic transfer of machine data from machine controls
Supplementary manual data collection via shop floor terminals, machine control or simple input devices
Compression of collected data to calculate KPIs according to VDMA 66412 (ISO 22400)
Visualization of reliable diagrams and pivot tables
User friendly shop floor monitor to display the machine park which can include current information
Preventive and proactive support of machine maintenance
Additionally, HYDRA MDE can be tightly integrated with other HYDRA applications as required. Examples include:
Shop floor scheduling
Shop floor data collection
Premium & incentive wages
Quality management
As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to integrate your requirements into the system conveniently.
Functions
Motivation increasing productivity
With the help of HYDRA MDE you can monitor your machines in real time, and react immediately in the event of malfunctions, or analyze the situation retroactively and thus optimize machine runs in the long term. The aim is to improve machine utilization and increase productivity.
Data collection
HYDRA MDE collects data from machines and systems of all kinds. HYDRA communicates via standardized or proprietary interfaces and protocols.
Example functions
Fully automatic collection of quantities, linear meters or interfering signals by means of inexpensive machine interfaces
Connection of machinerelated subsystems (e. g., Arburg computer system ALS)
Support of all standard protocols and interfaces to machines or controls (e. g., OPC, UMCM, XML, FTP, Euromap 63 and many more)
Manual recording of machine status: setup, startup, organizational downtimes (no material, tool missing, maintenance waiting) and technical interruptions (tooling issues, electrical or mechanical failure)
Real time monitoring
HYDRA MDE visualizes the collected machine data in real time. Different displays are available per application. Thanks to this capability, the responsible employees can immediately see where action is required.
Example functions
Shop floor monitor for office PCs and large screens in the production hall
KPIs displayed on the shop floor for the machine operator
KPI monitor for degree of utilization, Overall Equipment Effectiveness (OEE) and other KPIs
Data basis to make decisions
HYDRA MDE supports machine-related weak point analysis and provides the basis for investment decisions. A large number of flexible evaluations are available for this purpose.
Example functions
Machine history and time profiles
Downtime course and usage recorder
Analysis and hit list of status reasons
Evaluation of resource performance accounts (RPA)
Quantity and time-related performance reports
Maintenance
HYDRA MDE supports both preventive and conditional maintenance strategies. Data can also be made available for predictive maintenance.
Example functions
Graphical presentation of machine cycles and number of strokes
Evaluation of downtimes and failure classification
Maintenance calendar to specify and monitor maintenance intervals
Flexible data organization
Most companies produce on a variety of machines and systems from different manufacturers. HYDRA MDE offers user-friendly and comprehensive configuration options for the integration into the heterogeneous machine park.
Example functions
Grouping of interlinked machines, aggregates and handling devices into production lines
Individual configuration of collection dialogs and functions for displaying information on the shop floor terminal
Machine overview with configurable layout and content
Mapping of complex condition models for comprehensive error analysis
Display of individual requirements
As each manufacturing company has individual requirements, HYDRA MDE can be set up flexibly, which affords the customer the freedom to use these powerful functionalities as they wish.
Further details
HYDRA MDE can be configured via extensive master data and flexible settings without having to change the standard software:
Specification of shift plans and factory calendar
Specific catalogues for machine statuses, failure classes and RPAs
Rules for data collection and postings
Specification of maintenance intervals
Intuitive design of the shop floor monitor using drag and drop
Modern development tools are available to the user for more detailed individualization in the form of customer-specific evaluations and representations in HYDRA MDE.
Machine data as basis for numerous MES applications
HYDRA BDE can be integrated seamlessly into the network of production functions and supplies crucial data from production.
Further details
Integration into shop floor scheduling
Display of the current machine status
Use of quantities to calculate the remaining run time
Consideration of current performance values for improved planning based on real capacities
Temporary increase or reduction of machine capacity
Integration into shop floor data collection
Use of quantities to calculate the order progress
Correlation of setup times and interruptions with orders, operations, tools, batches and production lots
Integration into premium & incentive wages
Processing machinerelated data for the determination of incentivized wages (examples: Utilization bonus or premium based on the OEE)
Integration into quality management
Use of generated quantities or times to identify inspection due dates
Consideration of downtimes during the time monitoring of inspection intervals
Initiation of additional tests when changing the machine status
Integration into maintenance
Targeted planning of maintenance activities using the current maintenance calendar also for tools and other production resources
Database for modern maintenance strategies such as predictive maintenance

Application & benefits

Transparency and efficiency in any type of machine park!

In order to perfectly utilize available machines, manufacturing companies need to know how machines are currently used, as well as what potential can still be tapped from them. For this purpose, data must be systematically recorded and evaluated. A state-of-the-art machine data collection system, integrated in a Manufacturing Execution System (MES), offers the necessary range of functions to accomplish this.

Your Benefits

No more unreliable and time-consuming written documentation
Full transparency to current machine conditions
Improvement of maintenance processes based on reliable, actual data
Optimization of machine utilization by reducing downtimes and malfunctions
Longer machine utilization times and support for investment decisions

Machine data collection with HYDRA MDE

Both studies, and the experience from numerous projects, show that the average machine utilization is usually less than 60 percent. Unplanned downtimes have the lion’s share when it comes to wasting machine time with 10 to 15 percent. You can significantly increase machine efficiency by having reliable historical data on the machine behavior and thus you will have the background of all of its failures and malfunctions.

In addition to the order-related shop floor data collection, HYDRA MDE evaluates real time machine data recorded on the shop floor (e. g. machine status and quantities). Based on this, important KPI’s such as OEE (Overall Equipment Effectiveness) are calculated and then displayed in meaningful diagrams. From the collected data, you can find out everything you need to know about your machines, which is the first step in significantly increasing the availability and usage of your machines and systems. Combining this with a maintenance strategy (predictive maintenance), based on machine data, will result in higher productivity.

Furthermore, machine data enables reactive detailed planning on the shop floor, as well as forming a reliable basis for calculating premium and incentive wages.

Within HYDRA, MPDV offers the perfect supplement to the classic machine data collection when it comes to recording and evaluating energy consumption (HYDRA EMG) and process data (HYDRA PDV).

Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.

Highlights

Collect, evaluate and visualize data

You can cover all of the manufacturing processes with HYDRA MDE, from the collection to the visualization of machine data, using just one system. The evaluation of historical data reveals weak points in production and determines KPIs (e. g., OEE, efficiency) for production management and controlling.

In order to create the necessary transparency, the collected data must be up-to-date and reliable. For this purpose, HYDRA MDE offers a wide range of functions, including a mobile MES application.

Highlights of this solution are:

Automatic transfer of machine data from machine controls
Supplementary manual data collection via shop floor terminals, machine control or simple input devices
Compression of collected data to calculate KPIs according to VDMA 66412 (ISO 22400)
Visualization of reliable diagrams and pivot tables
User friendly shop floor monitor to display the machine park which can include current information
Preventive and proactive support of machine maintenance

Additionally, HYDRA MDE can be tightly integrated with other HYDRA applications as required. Examples include:

As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to integrate your requirements into the system conveniently.

Functions

Motivation increasing productivity

With the help of HYDRA MDE you can monitor your machines in real time, and react immediately in the event of malfunctions, or analyze the situation retroactively and thus optimize machine runs in the long term. The aim is to improve machine utilization and increase productivity.

Data collection

HYDRA MDE collects data from machines and systems of all kinds. HYDRA communicates via standardized or proprietary interfaces and protocols.

Example functions
Fully automatic collection of quantities, linear meters or interfering signals by means of inexpensive machine interfaces
Connection of machinerelated subsystems (e. g., Arburg computer system ALS)
Support of all standard protocols and interfaces to machines or controls (e. g., OPC, UMCM, XML, FTP, Euromap 63 and many more)
Manual recording of machine status: setup, startup, organizational downtimes (no material, tool missing, maintenance waiting) and technical interruptions (tooling issues, electrical or mechanical failure)

Real time monitoring

HYDRA MDE visualizes the collected machine data in real time. Different displays are available per application. Thanks to this capability, the responsible employees can immediately see where action is required.

Example functions
Shop floor monitor for office PCs and large screens in the production hall
KPIs displayed on the shop floor for the machine operator
KPI monitor for degree of utilization, Overall Equipment Effectiveness (OEE) and other KPIs

Data basis to make decisions

HYDRA MDE supports machine-related weak point analysis and provides the basis for investment decisions. A large number of flexible evaluations are available for this purpose.

Example functions
Machine history and time profiles
Downtime course and usage recorder
Analysis and hit list of status reasons
Evaluation of resource performance accounts (RPA)
Quantity and time-related performance reports

Maintenance

HYDRA MDE supports both preventive and conditional maintenance strategies. Data can also be made available for predictive maintenance.

Example functions
Graphical presentation of machine cycles and number of strokes
Evaluation of downtimes and failure classification
Maintenance calendar to specify and monitor maintenance intervals

Flexible data organization

Most companies produce on a variety of machines and systems from different manufacturers. HYDRA MDE offers user-friendly and comprehensive configuration options for the integration into the heterogeneous machine park.

Example functions
Grouping of interlinked machines, aggregates and handling devices into production lines
Individual configuration of collection dialogs and functions for displaying information on the shop floor terminal
Machine overview with configurable layout and content
Mapping of complex condition models for comprehensive error analysis

Display of individual requirements

As each manufacturing company has individual requirements, HYDRA MDE can be set up flexibly, which affords the customer the freedom to use these powerful functionalities as they wish.

Further details
HYDRA MDE can be configured via extensive master data and flexible settings without having to change the standard software:
Specification of shift plans and factory calendar
Specific catalogues for machine statuses, failure classes and RPAs
Rules for data collection and postings
Specification of maintenance intervals
Intuitive design of the shop floor monitor using drag and drop
Modern development tools are available to the user for more detailed individualization in the form of customer-specific evaluations and representations in HYDRA MDE.