Industrial automation systems | production monitoring

Real-time production monitoring and management system

for CNC machines

DPA provides a reliable source of information for managing and deviation processing in real time

Online demonstration

Scope of Applicability

Machining Process & Engineering Manufacture
Plastics Processing
Woodworking
Textile Manufacture

Benefits

Stability

Production System Maintenance

Monitor Equipment State
Prologning Machine Lifetime
Stabilize work on technology
Control Operation Duration
See Emerging Problems and Solutions

Punctuality

Basis of order execution on time

Control Production
Predict Turnaround Time
Sustain Turnaround Time
Execute in Reasonable Time
Orders on Time

Quality

Product and Production Processes Improvement

Technology Debug
Technology Upload
Technology Control
Technology Comparison
Technology Observance

Functional modules of the system

Monitoring

Machine data collection

Make decisions based on reliable and up-to-date information. We collect and store data from connected equipment in generalized and detailed forms, as well as in the context of the tasks being performed.

Up to 2,000 machine parameters, including:

machine status (production, on, off)
emergency stop
machine condition monitoring
information about the processing program (status, name)
position of the speed correctors
actual value of spindle speed and feed
values of program counters and machine cycles
spindle load (not supported by all models)
PLC memory locations

Analytics

Visualization and analysis

Displays important information for staff in an understandable way.

19 journals, 39 reports, ∞ dashboards

The Analytics module visually displays structured monitoring data in graphical and tabular forms.

Analytical data is available both in the form of reports and in the form of dashboards for real-time tracking of critical indicators.

The module allows:

See how the machine is used
Identify losses and their causes
Optimize technological processes and set up continuous production
Register and respond to alarm events and CNC signals
Anticipate and prevent emergencies
Receive alerts about deviations from technology

Control Program Library

Control programs

DPA can be used to transfer and download NC programs to the machine. Control programs are stored in a single library, taking into account versioning and access rights.

On most CNC controls, the system can track the NC programs that are actually being executed on the machine. In this case, not only the name of the NC program is taken into account, but the system also controls the content (body) of the NC program, which was actually executed on the machine, even if the NC program was loaded in a different way, bypassing DPA, or taken from the archive on the machine.

The module allows:

Load and store control programs
Manage versions of control programs
Indicate production of which products and at which work centers the program can be used for
Upload the control program to the machine (while the system monitors the state of the machine and does not allow interrupting the running program)

Technology

Operational cards and reference data

The module makes it possible to take control of all operations performed on machine tools.

Describe the processes used in production in terms of routes / stages / operations and get all the necessary information to manage and control the technological aspects of production.

The module allows:

Set up and describe the flow charts used in production
Operator to receive part design and technological documentation at each stage of production
Help the operator to follow the technology exactly when completing the production task
Take into account the norms, deviations and losses, the percentage of scrap and other parameters in the context of technological operations

Rationing

Controlling the duration of operations

The system allows you to store temporary norms for performing production operations, form or adjust them according to the production history, and monitor compliance with the norms when performing tasks.

Maintenance

Accounting and control of maintenance and scheduled work

Monitoring the correct use of equipment, drawing up and monitoring the schedule of scheduled maintenance. Accounting for accidents and unscheduled repairs.

Operator Automated Workstation

Functionality to monitor technology compliance at each stage of the shift and daily tasks. Collects data on time overruns of operations.

Enables you to contact quality control or any other specialist without having to leave your workplace.

The workstation allows you to note the causes of downtime, adjustments and equipment failures.

Technological documentation is always at hand.

Signals

Messages, signals, deviation handling

Generation of signals and notifications for specified conditions or deviations from the required values.

Transfer of notifications to personnel and control of specialists' reactions.

Upgrade

Connecting equipment without CNC

Equipment with Ethernet ports and support for OPC, OPC UA, Euromap, MTconnect protocols can be connected to a unified production data collection system. DPA can act as both a client and a server of these protocols.

Equipment with standard controllers OMRON, Siemens, Schneider, Beckhoff, etc. in the presence of a controller project.

Our partners produce additional equipment to link machines without CNC, when it is economically feasible.

Vibration diagnostics

External vibration diagnostics systems can be connected to the DPA system to monitor processing and equipment condition.

Data Integration

ERP Actualization

Business processes supported by automated control systems will be more efficient by supplying reliable production information automatically. Monitoring systems transmit information on quantitative and temporal indicators directly to the ERP system.

MES Basis

Monitoring can be the basis for the MES development (Full-function Production Management System). Already today's functionality allows taking control of basic processes and getting a clear benefit. It is therefore possible to consider the further development of the production system accordingly.

PLM Development

There is a rationale to focus on the integration of PLM-MDC (moving from “Digital Part” to “Digital Production”) for enterprises with complex products and a well-developed circuit (CAM / CAD / CAE / PLM).

Learn more about Integration