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HYDRA Machine Data Collection
Efficient Utilization of Machines
Machines can be used much more efficiently than you may consider possible – provided that you know the reasons for downtimes and malfunctions. There is a tool that records machine data with minimal effort and evaluates it based on your requirements: it is the Machine Data Collection module (MDE) of the Manufacturing Execution System (MES) HYDRA. This system provides you with all the necessary information about your machines – which is the first step to considerably increase capacity utilization rates
and the availability of your machines and equipment.
The figures show how much potential is still available: The average machine utilization amounts to less than 60%. Unplanned downtime accounts for 10 to 15% of the waste potential.
HYDRA-MDE is a tool used by many production companies that records machine data with minimal effort and evaluates it according to your individual rules.
Create and Manage Master Data
You can define what data are collected by which machines and in what form and how results are calculated and presented:
• Create and manage machine master data
• Configure shift plans and factory calendars
• Define machine statuses and resource performance accounts
• Specify the rules for data collection and posting
• Fix maintenance intervals for plant maintenance
Manual Data Collection
Operators and setters can post machine statuses and equipment statuses either manually or by using appropriate terminals:
• Setup, startup, production
• Organizational downtimes (no material available, tool missing, waiting for maintenance)
• Technical malfunctions (defective tools, electrical or mechanical malfunctions)
Automatic Collection of Machine Data
HYDRA-MDE provides a variety of technical possibilities to connect machines to the system. Quantities, running meters or disturbance signals may be recorded directly by using digital inputs and by connecting sensors to the machines. As an alternative, HYDRA-MDE uses data interfaces to communicate with machine and system controls. Consequently, the data saved in SPC are uploaded automatically, e.g., quantities, statuses
and malfunction times. HYDRA supports common logs and communication technologies, such as OPC, XML, Euromap and Profibus.
Machine Monitoring
Using HYDRA-MDE you can monitor your machines in real
time – consequently, you can immediately respond to problems.
Examples:
• Overviews on the current machine status
• Graphic machinery displaying the statuses of all machines of a plant or factory
The configurable “graphic machinery” shows the current status of machines and equipment.
• Determination of cycle times and stroke numbers
• An online maintenance calendar with traffic light function (RAG status) supports your maintenance activities
• Monitoring of machines with the browser-based machine monitor via Internet or smart phones
• Escalation management: signaling of malfunctions by SMS or e-mail to the appropriate recipient
Data Evaluation
Machine data evaluation reveals problems in production and determines key figures for controlling or maintenance. Examples:
• Evaluation of downtime and disturbance classes in tables
• Downtime development, utilization recorder, machine time profiles
• Reports about production lines including interlinked machines, aggregates and handling devices
• Calculate capacity utilization rates according to individual rules
• Graphic presentation of the machine’s cycle and stroke performance
• Performance reports relating to quantities and time
• Key figure monitor including calculations on Overall Equipment Effectiveness (OEE), Total Productivity Indicator (TPI) and many other key performance indicators
• Long-term archives for machines, machine groups or cost centers
Key performance indicators are calculated at the push of a button based on general or company-specific specifications.
Using the configurable MDE functions, users can view the data they require for monitoring machines.
Special HYDRA-MDE reports show which malfunctions occurred at the machines, providing details about frequency and times.
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