Success Factors for Machine Connection

In today’s manufacturing facilities, there is a large mix of heterogeneous machines and control types, where signals must be collected, aggregated and evaluated. The solution to this common problem is a centralized system, which can seamlessly “plug and play” with any type of machine CNC controller or PLC. However, machine connection and integration capabilities are key differentiators when selecting the right MES technology provider. The experience level and readiness of the technology provider determines the time and costs required to successfully connect any machine. Standardized interfaces to all common machine controls, via direct plug-ins, must be created, otherwise the time required for connecting the machines, is unmanageable. In a pilot project initiated by an MES provider, a major German tool manufacturer determined that connections to some of their machines were very time-consuming, costly and in some cases not possible. Even after months of work, some challenging machine controls types remained unconnected. The MES provider lacked expertise and the necessary plug-ins.

The customer in this case study is a major German tool manufacturer. The company operates a modern shop floor and aims to measure and visualize the performance of machines and systems in real time. The company's goal is to create a transparent factory, where production is virtually mirrored and inaccuracies and wastes can be immediately identified and eliminated. The company aims to create a “Cyber-Physical System” that can analyze and optimize the performance, availability and quality of the production processes, leading to productivity increases of 20% or more within 12 months or less. However, the company faced challenges in connecting to some of their machines, which was very time-consuming, costly and in some cases not possible.