Manufacturing Data Collection (MDC) and Monitoring
Manufacturing Data Collection (MDC) and Monitoring
This is a complete MDC solution that enables automatic collection of manufacturing data from machines and personnel in real-time. MDC provides accurate data for identifying causes of production loss, potential areas of improvement and enables real-time monitoring of your shop floor for continuous improvement.
Generate reports and charts with automatic calculation of OEE, cycle time, idle time, setup time, downtime
Equipped with real-time machine monitoring with Live Screens
Enables one man operation with a few machines and the corporate enterprise with multiple factories
A networked solution that stores data on a central server you can monitor production from multiple locations and access the data form anywhere.
INCREASE PRODUCTIVITY
Whether you want to increase your existing level of productivity, identify production bottlenecks or streamline workflow – our MDC is the solution of choice
Kewpump Increases Productivity Using CIMCO Manufacturing Data Collection
Kewpump is a leading industrial pumps manufacturers and innovative pump solutions provider in Southeast Asia, spanning a diverse range of markets, from oil and gas to chemical processing to waste water treatment to consumer goods. Kewpump today have products installed in more than 40 countries worldwide.
Kewpump adopted manufacturing data collection and have successfully achieved higher productivity and enabled data-driven decision-making with shopfloor data digitisation and IoT.
BENEFITS
Reduce administration time
Reduce paper reliance and administrative time. Update your ERP, MES or other administrative system directly with real-time data as it is received from equipment and personnel.
Understand the performance of equipment and personnel with accurate real-time data collection. Identify causes of production loss and potential areas of improvement for better utilization of resources and data-driven process adjustments.
Accurate data collection
Eliminate those manual, time consuming and often inaccurate data collection by automating and streamlining the data collection process.
Eliminate guesswork. Understand the inner workings of your production with customized real-time and historic reports including machine downtime, OEE and other essential KPIs.
Access your data anywhere
Access data from one or more sites directly from your mobile device. Easily check the status of equipment or any other information critical to your operation
Monitor and visualize the performance of equipment and personnel to improve response times, identify potential errors early, and improve overall company communication. Improve operator engagement through data-driven awareness.
WHY INVEST?
- Finds manufacturing problems within 24 hours of installation.
- Tracks reasons for machine down time.
- Increase machine utilization and meet production targets which increases profitability.
DATA COLLECTION
When we talk about data what we actually mean is events. The first task when installing MDC is to consider what machine and operator events you want to collect information about.
Machine events can be collected automatically by MDC and most installations will include events such as Cycle Start, Cycle Stop, and Part Complete as a minimum. When these events occur at a machine MDC is automatically notified and data about the event is stored.
Operator event data is sent manually by machine operators. Using a smartphone, tablet, barcode scanner or PC an operator at a machine can send status information to MDC indicating specific events. Usually you want to collect downtime reasons such as Waiting for Setup, Waiting for Maintenance, Scrapped Part, Inspection, etc. MDC can be customized to collect specific information on any event.
HOW DOES THIS WORK?
BASIC SETUP FOR MACHINE DATA COLLECTION
The majority of companies only want to know if a particular machine is running and producing parts or if it is stopped.
With a basic data collection setup MDC can show the amount of time the machine has been in production and the amount of time allocated to downtime.
ADVANCED SETUP FOR MACHINE DATA COLLECTION
With the advanced data collection option MDC can provide accurate reporting of machine tool efficiency on any job. MDC can show the total percentage of downtime for each type of machine stoppage such as Tooling, Setup, Machine Maintenance, etc. This additional information is provided by the operator using a tablet or a barcode scanner. The operator uses the tablet or simply scans a barcode to indicate the downtime reason. This information can then be used to pinpoint exactly what is causing a loss of production.
REPORTS AND GRAPHS
In MDC, data is structured and visualized as reports. You can setup our MDC to generate both real-time and historic reports based on the data collected.
Our MDC features a modern tabbed interface where each open report is shown in a separate tab. This maximizes screen space for each report while allowing many reports to be open and updating in the background.
Our MDC comes with built-in reports, but the true power lies in its ability to create customized reports. Visualize data as tables, pie or bar charts, add in production targets, work shifts, calculate key performance indicators such as OEE, MTBF, MTTR, and more. You can also generate event logs chronologically by operator, machine, and job to know exactly how each machine and operator is performing.
Our MDC supports dynamic reporting where data is updated in real-time. Machine status can be visualized as timelines or Gantt charts with status changes shown with different bar colors so you can see at a glance what is going on.
EXAMPLE OF REPORTS
- Cycle time per part (min, max and average)
- Number of parts per shift/operator
- Number of scrapped parts
- Machine downtime
- Scheduled maintenance
- Unscheduled maintenance
- Setup time per part
- Operator effectiveness
- Overall Equipment Effectiveness (OEE)
- Mean time between failures (MTBF)
- Mean time to repair (MTTR)
REAL TIME MONITORING
One of the unique features of CIMCO MDC-Max is our Live Screen which provide a great status overview for every machine and can be displayed on large plasma or LCD screens. This Live Screen can be configured to show a list of all machines and their current status. Further, data such as machine name, job name, part count, running time, downtime, etc. can be associated with each machine to provide a complete overview.
The Live Screen is normally displayed on large screens that are installed in convenient locations so that all personnel can easily see the status of each machine. However, it can also be displayed on smartphones, tablets, and touch screens using the MDC-Max Web Client and can thereby be viewed from anywhere there is an internet connection.
If machines are running unattended MDC-Max can even be configured to send an email and a text message to a stand-by operator’s or supervisor’s smartphone if a machine stops.
HANDHELD OPTIONS
MDC WEB CLIENT
With the MDC Web Client we have taken operator events to the next level. The web client can display your live screens and be customized to send any operator event you can think of. Machine status and operator events can be accessed directly in the web client interface making it extremely easy for operators to send downtime reasons for a specific machine.
The web client is optimized for even the smallest displays using responsive design techniques. This means you can access the same interface on smartphones, tablets, and PCs. Thereby the traditional operator screen at the machine has become mobile and can fit in every operator’s pocket. This is not only convenient for the operator, but also a cost-efficient alternative to having client PCs or bar code readers installed at each machine.
DNC-MAX WEB CLIENT
Our innovative DNC software includes a new web client that can be accessed from any mobile device or PC. The DNC-Max Web Client can display the current program transfer progress and state of all your machines. You can send, receive, and preview CNC programs using a built-in file browser showing your files on the DNC-Max Server – just like with our regular DNC-Max PC client. It is even possible to stop transmission of programs, restart ports, and also remove programs from the transmission queue directly from the web interface.
Please contact us for more information about how DNC-Max can seamlessly integrate with your MDC solution.
SYSTEM INTEGRATION
INTEGRATION WITH OTHER SYSTEMS
MDC-Max comes with full support for Microsoft Excel spreadsheets. Reports can be exported easily for further analysis in Excel. MDC-Max can even update your Excel spreadsheet automatically, so the latest data is always available.
MDC-Max can also be integrated with most ERP/MPS systems on the market. This means you can have a completely integrated solution that can significantly reduce administrative tasks.
EXTEND WITH SOFTWARE
MDC-Max can be fully integrated with DNC-Max, NC-Base and MDM giving you a complete DNC, manufacturing data management, and machine data collection system from one supplier. DNC-Max controls CNC program transfer to all of your machines. Programs can be requested directly from the machine control – operators do not need to leave the control to download programs. A program that is changed and uploaded by the operator can automatically become the active version of the program while storing the previous version as a backup copy of the file or the uploaded file can be stored in a quarantine area. This offers the ability to track changes and revert to any previous version if necessary.
NC-Base and MDM are both full featured manufacturing data management systems that help you manage, control and securely store your manufacturing related data. While NC-Base is ideal for handling your NC-programs and related documents, MDM can be customized to handle any kind of data such as CAD/CAM programs and any related documents.
NETWORK OPTIONS
DIRECT CONNECTION
If the machine you wish to monitor has one of the data collection interfaces available (see table below), a direct connection can be achieved by simply connecting an Ethernet cable to the machine. In this case no additional hardware is required beyond what might be needed for operator input (e.g. tablet). However, it can be costly to activate or install the monitoring feature if not enabled on a machine control and a Hardware connection might be preferred.
If your machine does not support one of the monitoring interfaces signals can be acquired from the machine using an input device such as the MDC-Box or Moxa ioLogik device. These devices handle the connection between your machine and network and facilitate signal transmission, in the form of machine event data, to MDC-Max.
Many manufacturing facilities are networked, with Ethernet available at each machine. Standard Ethernet hardware (switches, routers, bridges, etc.) are used to connect the machines to the network.
Wireless networks on the shop floor are becoming increasingly popular. If you expect to move or add machines a wireless network eliminates the need to run or re-route cables.
Supported machine controls
The following machine controls are just some of the many controls we support for direct connection. If your control is not listed please contact us for information about your specific machine and control.
| Control | Required interface | Extent of data access |
| Fanuc | FOCAS | Full compatibility |
| Haas | M-Net | Full compatibility |
| Mazak | MTConnect | Full compatibility |
| Okuma | MTConnect | Full compatibility |
| Mitsubishi | MTConnect | Full compatibility |
| NUM | MTConnect | Full compatibility |
| Heidenhain | DNC Opt #18 | Full compatibility |
| Siemens (840D, 810D) | Hardware adapter | Most compatibility |
We are continuously adding support for additional machines.
How to start monitoring your production with MDC?
1 Understand
2 Deliver
3 Implement
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