Predictive Maintenance & OEE Monitoring
The Challenge
A machine park with heterogeneous control versions provided no comparable data. Downtimes were only noticed after they occurred, reducing Overall Equipment Effectiveness (OEE).
The Implementation
Implementation of a central data collector via OPC UA. Programming of data blocks within the controllers to provide status and piece count data. Processing of raw data in an SQL database for OEE metric visualization.
Result
Real-time transparency across the entire machine park. Introduction of preventive maintenance planning based on actual operating hours instead of fixed intervals.
Fully Automated Production Workflow
The Challenge
Orders from an online shop had to be manually translated into production jobs. There was no feedback loop from the machine back to the sales system regarding manufacturing status.
The Implementation
Development of a Java-based middleware that verifies incoming orders, checks material availability, and distributes jobs directly to the appropriate machine. Additionally developed an Android app for operators to monitor progress remotely.
Result
A fully automated chain from the customer's click to the machine start. Massive time savings in production planning and error-free data transfer.
Automatic Clamping Situation Display
The Challenge
When selecting an NC program for execution, the operator should automatically see the required clamping setup (e.g., spacers, fixtures) on the machine display.
The Implementation
Development of a Java desktop application that reads the program header via OPC UA, identifies specific syntax-coded information, and displays the corresponding PDF setup sheet in a viewer.
Result
Prevention of machine crashes caused by incorrectly loaded workpieces and enhanced operator guidance.
Automated Quality Correction
The Challenge
Quality assurance measurement results were manually evaluated, and correction values had to be typed into the machine by hand—a time-consuming and error-prone process.
The Implementation
Development of a software solution that automatically imports CSV measurement logs, calculates deviations, and generates optimized correction programs directly for the machine tool.
Result
Implementation of a "Closed-Loop" process. Reduced scrap rates and freed skilled personnel from repetitive calculation tasks.
PDA Terminals & Time Tracking
The Challenge
Working hours and job times were recorded on paper. Precise post-calculation for complex components was nearly impossible.
The Implementation
Programming of intuitive Production Data Acquisition (PDA) terminals directly at the machine, alongside a mobile Android solution. Employees log into jobs via scan or touch interface.
Result
Precise data foundation for cost accounting. Digital transparency regarding the real-time status of all active jobs on the shopfloor.