Zyfra develops industrial digitalization technologies, invests in such products and improves the Industrial Internet of Things and Artificial Intelligence environment. Company's key fields of industry are machinery, metallurgy, mining, oil & gas and chemical enterprises. We promote readymade industry solutions in predictive analytics and data analysis, tech processes optimization, machinery and floor staff monitoring.
08 February 2019
acting digital advisors and digital doppelgangers
Zyfra MDCplus: manufacturing data collection (MDC) system
Do you know what actually happens in your workshop?
To make effective decisions, you need objective information. The first step to increasing productivity is real-time personnel and equipment monitoring.
Zyfra MDCplus is a real-time machine monitoring and manufacturing data collection (MDC) system with hundreds of customizable reports and charts that can be used to track jobs, parts, operations, work centers, OEE, scrap, costs, downtime and people.
MDCplus key features
Monitoring of equipment states and downtime reasons in real time on a linear chart, in a table, or on a facility floor plan;
Monitoring of equipment operation parameters (current, power consumed, temperature, speed and feeds, JOG correctors, spindle and axes load, PLC signals, etc.);
Control of equipment power consumption parameters;
Detailed info for each machine (event log, error log, list of measurable parameters for the machine, process information, etc.);
Video monitoring of production areas, option for video capture of individual events;
Setup of controlled events and notifications for appropriate company units (e-mail, SMS);
Reports generation for company managers and units with automatic distribution according to a set schedule;
Display reports on the monitor (TV panel) on the facility floor and on mobile devices (tablets, smartphones);
Trends in equipment and staff performance analysis;
Calculation of key performance indicators (KPIs) for equipment and staff, including OEE, as per ISO 22400-2 2014. KPIs can be calculated based on user-defined formulas.
Production monitoring module
Monitoring of manufactured output and scrap;
Control of the time standards for the execution of technological operations;
Control of telemetry parameters during manufacturing output in order to reduce spoilage;
Generation of shift tasks, routing sheets, and orders;
Report generation on manufactured output and rated time and KPI calculation, including OEE.
Vibration Monitoring and Diagnostics module
Measurements of key parameters characterizing the technical state of key machine components;
Comparison of parameter values with permissible levels and alerts generation when permissible levels are exceeded;
Send data on the actual state of equipment components to the CMMS system;
Crash and impact detection with issuing machine shutdown signals;
CNC Program Management Module
Storage of NC programs;
DNC Communication (ETHERNET, USB, RS232, IFSP);
Analysis of NC program usage and comparison of the code with the standard.
Downtime Management Module
Dispatch of non-scheduled (emergency) repairs and maintenance;
Scheduling of MRO operations based on work hours and actual states of the CNC machine;
Control of the execution of scheduled repairs;
Management and recording of the work of maintenance and repair staff;
Management of procurement for maintenance and repair services;
Documentation support of maintenance and repair operations;
Interaction with external service providers.
API connection for external ERP, CAD/CAM/PDM, MES and BI systems
Synchronized reference data;
Sending documents (order, shift task, routing sheet);
Obtaining actual data (order/operation/machine operation/equipment/employee);
Obtaining any CNC machine operation data.
Data collection scheme
FAMILY OF ARTIFICIAL INTELLIGENCE PRODUCTS
High-accuracy forecasting, real-time recommendations, and decision-making process automation — which is the most complex and costly production process
How it works
Taking efficiency and safety of the mine to the next level
- Smooth production process
- Detection and identification material and energy losses in manufacturing operation
- Optimized cost of quality control operation in production cycle
- Timely and sufficient equipment maintenance
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