Machine Data Collection in Manufacturing

Machine data collection is an important component for successfully implementing your digitalization strategy. When machines, production lines, and systems are networked, important machine data generated during manufacturing processes can be automatically collected and immediately processed and analyzed. A machine data collection system identifies valuable productivity potentials in production processes so that they can be leveraged for the long-term optimization of production workflows.

L-mobile’s software for machine data collection seamlessly and reliably records data to deliver high transparency and real-time availability of your manufacturing data. The solution gives you an ideal basis for creating efficient, on-time, transparent manufacturing.

Increase the transparency and efficiency of your manufacturing with machine data collection

Today’s computer-controlled machines are able to communicate their operating states automatically. Wouldn’t it be ideal to collect this data with a software solution, analyze it, and use it to increase the efficiency of your manufacturing? This is exactly where the Machine Data Collection system from L-mobile comes in: machine data collection enables you actively link your manufacturing order with the physical machine status. This connection makes it possible to collect order-related machine data, such as operating status, idle times, output, or process data, continually and in real time. The result is a comprehensive set of data from the collected machine data, which is aggregated and visualized in real time. Ultimately, this provides starting points that lead to optimizing production processes and effective machine utilization.

Standalone solutions collect and map machine data in a separate system whereas the L-mobile Machine Data Collection system directly reports all collected machine data to the central ERP system. This way you can ensure a continuous information flow and always gives you access to current and historical machine data.

So what are the advantages of machine data collection? Thanks to the automated collection and analysis of all machine-generated production data, the data quality of the recorded machine data is considerably improved. At the same time, you achieve consistent data transparency because you are continually updated on the current statuses of your ongoing manufacturing orders. The continual monitoring of manufacturing processes positions you to recognize potentials for improvement at an early stage and implement suitable measures in a timely manner. This way you can quickly eliminate weak points and disruptive factors, such as inadequate quality of your raw materials or tools.

4 advantages of machine data collection

Your path to digital and networked production

L-mobile digital production, advantages of machine data collection

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Advantages of machine data collection

Reduced costs through optimized manufacturing processes

Optimal machine utilization

Avoid idle times

Reduce collection and response times

Reduce pressure on personnel resources

Improved planning and maintenance intervals

Shorten setup and throughput times

High quality of collected data

Improve on-time delivery

Using L-mobile machine data collection to record machine data

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Using machine data collection for your production
In our free webcast, we show you how to accurately and continually digitalize your manufacturing data in real time with machine data collection.
Live demo of the most important functions
We give you a look at how the software solution functions and how machine data collection and production data collection work together.
Helpful practical examples
Examples from our customers’ operations show just how different applications scenarios for a machine data collection system can vary.

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Increase your manufacturing productivity with a machine data collection system

Mit Maschinendatenerfassung (MDE) und predictive maintenance zur 0-Fehler-Produktion

With machine data collection, you can achieve growing data quality in your manufacturing step by step. Based on thisreliable foundation of data, you can identify potentials for optimization or weak points and implement suitable measures. At the same time, the system can predict when interventions make sense, even without the threat of downtime, such as with increasing scrap quantities.

L-mobile machine data collection supports you in monitoring your processes: tolerance thresholds can be defined and messages can be sent in the event of deviations. Through early interventions and fine-tuning, you can achieve long-term increases in your productivity.

How machine data collection works

Machine terminal and machine monitoring system

L-mobile digital production – Data collection Production data collection Machine data collection

The machine terminal

Flexibly mount terminals directly on the machine
Seamlessly record production data without errors
User-friendly interface
Select orders and start operations
Malfunction notifications, quantity postings, setup
Direct connection to the ERP system
Machine status feedback in real time

The machine monitoring system

Your early warning system for production
Live visualization of manufacturing data
Easy-to-read color codes
Machine status and any malfunctions at a glance
Displays production quantity and cycle time as actual/target data
Current ratio between yield and scrap quantity
Deadlines

L-mobile Digitalisierte Produktion - Datenerfassung BDE Cockpit

Which machine data does a machine data collection system record?

Increase data transparency in manufacturing with software for machine data collection

L-mobile’s machine data collection software reliably provides production-specific key figures comprising the following values:

Central process values
Utilization level (run time/length of shift)
Output (IO amounts/NIO amounts) – piece counter
Performance level (Te/target Te)
Setup level (Tr/target Tr)
Quality level (IO amounts/NIO amounts)
Efficiency (OEE for short disruptions)

Secondary process values
Pressure values: Oil/hydraulic, pneumatic
Flow values
Temperatures
Energy usage
And much more
Efficiency (OEE for short disruptions)

The machine data collection process

How digitalized machine data collection functions with machine data collection software

Pre-planning
Pre-planning an order, such as in the ERP system

First, a rough planning of our orders is drafted, for example in your ERP system.
Detail planning
Machine, tool, deadline, amount, approval

The L-mobile APS automated production planning software creates optimal plans for manufacturing runs, even complex ones. Thanks to the integrated optimization algorithm, the APS generates a production plan that is always feasible and cost-optimized.
Manufacturing
Malfunction notification, quantity posting, statuses, setup

When the order is sent to manufacturing, production data can be recorded, in addition to the automatically generated machine data. L-mobile production data collection software continually reports on the status of a manufacturing order—from the start to order completion.
Control
Completion, final costing

The recorded machine data and production data are combined in the L-mobile productivity cockpit to give you an overview of your manufacturing processes at all times.
Order completion
Completing an order in the ERP system

In a last step, the order is completed in the ERP system.

In the field: how the Pirlo Group uses digital machine data collection

The Pirlo Group wanted to find a digital solution for collecting and processing production data rather than continue to record it on paper and then manually enter it into their ERP system. The longstanding company manufactures metal and plastic packaging. The core of its business is the organization of efficient warehouse and production processes.

To simplify and accelerate the collection and processing of data in its production, Pirlo decided to implement software for production and machine data collection. Meanwhile, 90 machines are linked to L-mobile production and deliver valuable real-time data on production processes. The machine data collection system automates the recording of machine-related data, such as produced quantities or speed. Additionally, other data, such as setup times or malfunctions, are conveniently and easily recorded on production data collection terminals.

Digital data collection and processing ensures consistently digital and fast processes. Moreover, the recorded real-time data can be used to identify other starting points for optimizing production. Besides the production and machine data collection software, Pirlo is also running the digital warehouse management solution, L-mobile warehouse, to simplify warehouse work and make it mobile.

Exchanging machine data with other systems

Machine data collection software ensures a reliable data flow of production data

The machine data collection system is the interface between your diverse machine technologies and consistent information processing, ensuring a continual flow of information between manufacturing and your back office. The SCADA server (Supervisory Control and Data Acquisition) processes, interprets, and distributes your data so that it is always available in real time in the right places. This allows the data to be fed into manufacturing planning software (such as the L-mobile APS), the productivity cockpit to visualize your manufacturing, a data analysis tool (for example L-mobile production data collection), or directly into your ERP system.

Beispielaufbau der Maschinendatenerfassung mit L-mobile MDE

Which machines can be connected to L-mobile machine data collection?

L-mobile digital production – Connection of different machine types to L-mobile machine data collection

The L-mobile machine data collection software can be linked with all machines equipped with a systematic and technically designated interface.

Machines that send signal data via an OPC UA-type interface are especially easy to connect. OPC UA refers to architectural specifications that have meanwhile been adopted by many machine manufacturers and are becoming more widespread.

If a machine cannot be connected via a more modern interface, another option is to add external hardware to the machine. If external hardware can be used to monitor a machine’s status, there is no qualitative difference in signal data acquisition compared to modern machine interfaces.

Application examples for machine data collection

Machine data collection software can be used for various applications

L-mobile has already helped several companies successfully navigate digitalizing their manufacturing processes. We are able to draw from a great deal of experience, including projects with very individual and complex process flows. In collaboration with our customers, we bring digitalization to the entire scope of a manufacturing landscape so that processes seamlessly function. We were able to meet and resolve these challenges in one of our customer projects:

L-mobile digital production – L-mobile machine data collection Assigning the scrap quota to a manufacturing order

Defining and assigning the scrap quota to a manufacturing order

As part of machine data collection, all of a customer’s machines were connected to L-mobile via direct signal data acquisition. Previously, it had been very difficult to determine whether or how much scrap was generated in manufacturing. This was because the same material was used for multiple, successive manufacturing orders and had to be assigned to the product with a time delay.

Through an OPC data link, both run time statuses and quantity notifications are now recorded. In addition to the produced quantities, the main product components are connected to a separate counter. L-mobile machine data collection makes it possible here to determine the scrap and clearly delineate thetime delay between the materials usage and creation of the product. The scrap quota is directly assigned to the relevant manufacturing order.

L-mobile digital production – L-mobile machine data collection final packaging

Control along the entire process chain

In the final packaging area, coordination between the machine and L-mobile means that a pallet is packed, conveyed, and labeled approximately every three minutes at our customer’s plant. In another section, the products are first placed on pallets, forwarded for strapping and stretch wrapping, and then sent to shipping in an elevator.

All process steps require a combination of data from the production lines, the ERP system, and L-mobile. The entire process chain is controlled by L-mobile in coordination with the production line OPC controllers. Approximately 70 machines are at work here and around 20 OPC servers. Cockpits at every work station and multiple individual pieces of work station equipment support the entire process.

L-mobile digital production – L-mobile machine data collection Process reliability thanks to machine data collection system

Secure processes, even if employees are not trained in detail

Until recently, these processes could only be properly run by highly trained employees. The new solutions mean that employees now only have to intervene at specific stages. Thanks to the new visualization and time-accurate display from L-mobile, processes can be carried out even if the operator only has limited knowledge of the steps involved.

L-mobile digital production – L-mobile machine data collection Exact batch tracking by using a machine data collection system

Exact batch tracking and unfinished goods

In another product area, around 150–200 pallets of saleable goods are produced per day. Manufacturing is scheduled in several runs, which means that the inventory of unfinished goods must also be recorded. This is where batch tracking comes into play. Previously, the system was not able to track and identify pallets as a container, but the L-mobile solution now makes it possible to perform exact batch tracking and locating of pallets.

L-mobile digital production – L-mobile machine data collection Seamless production processes through offline availability

Automated packaging during an ERP system outage

One of the goals of the customer project was to ensure automated processes, even in the event of ERP system outage during day-to-day operations. L-mobile has made it possible for the customer to run all aspects of its production and produce labeled stock, even without a connection to the ERP system. All processes send the generated data to the ERP system as soon as the connection is restored.

Technical features & advantages of L-mobile’s machine data collection

Proven 24/7 operations

Real-time availability of current data in the ERP system

Combination of manufacturing and warehouse hardware

Connection of an unlimited number of machines

Unlimited number of different interfaces

Integration of machines without interface

Increase the performance of your manufacturing processes with an MES

Discover our modular MES solutions, which can be individually integrated into your existing process landscape or run as a complete solution. These mobile software solutions will increase the transparency and efficiency of your manufacturing processes—from production planning and machine connection to order processing. We use state-of-the-art technologies, such as RFID, UWB, E-Kanban or Pick-by-Light, tools that allow you to monitor your production processes live.

L-mobile production data collection

What if you were able to stay informed at any time about the current status of your manufacturing? L-mobile production data collection facilitates precise and seamless data collection for all production steps, including the start of the manufacturing order, setup time messages, malfunction times, the source of a malfunction, and completion of a production order. Real-time feedback from your employees means you can always keep an eye on your production while also generating a valuable data set that lets you draw conclusions about optimization potentials.

More information

L-mobile quality data collection

Designing smooth, transparent manufacturing processes is as important as ensuring the quality of produced goods. A best practice to achieve this is building in quality assurance upstream in manufacturing. An inspection plan is used to define at which steps tests should be run within manufacturing processes. The generated data serves as a basis for drawing important conclusions about the quality of finished parts. In line with the concept of the smart and networked factory, L-mobile quality data collection can be combined with other MES modules, such as L-mobile machine data collection or the L-mobile SCADA server.

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L-mobile digital assembly instruction system

Does your manufacturing involve a lot of variants? The L-mobile digital assembly instruction system supports even complex and variable assembly processes by always providing the correct digital assembly instructions. Through the use of auto-ID technologies like RFID and UWB, manufacturing orders are digitally identified and the system then makes the relevant instructions available. The various components of the digital assembly instruction system offer an ideal basis for networked, automated production, including integrated quality data collection, quantity notifications related to production data collection, and the display of machine data.

More information

Successfully navigate the path to digital and networked production with machine data collection

L-mobile is your strong partner and Industry 4.0 expert on the road to digitalization

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Networked business processes and an optimal value stream

From digital warehouse management through production and machine data collection to production planning in 3 steps

How do mid-sized manufacturers successfully navigate the path to the digital and networked factory? Which aspects are important in developing a holistic digitalization strategy? And what will be required of the IT system to ensure company-wide data networking?

Today, medium-sized companies face a variety of challenges. They need innovative and future-ready concepts that ensures they remain competitive and prepared for what lies ahead. For manufacturing companies, this means increasing transparency in the company—from purchasing, warehouse management, and production to sales. Processes and production lines must be networked in order to provide the right person with the right information at the right time. And finally, integrated IT systems make it possible to completely aggregate and prepare data in high quality and use it to optimize business processes. The digital networking of warehouse management, machine data collection, production data collection, and production planning creates a basis for recognizing error sources and bottlenecks and developing sustainable measures to optimize processes. Please refer to our free whitepaper to learn more about how networked business processes for generating data can be implemented in three steps.

Digitalization strategy

For medium-sized manufacturing companies

L-mobile whitepaper: Digitalization strategy for mid-sized production companies – Optimized value streams through the data networking of systems and processes

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Would you like to learn more about paperless, networked production? In our award-winning Digital Factory, you’ll experience how a warehouse and production can be ideally networked with the right software and hardware. During your virtual tour, you’ll learn about our seamless digital solutions, including digital order intake, the digital assembly instruction system, and RFID-supported shipping and reporting. Visit us in person at our headquarters or view our video series from the comfort of your own home to learn about our Digital Factory.

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L-mobile machine data collection, easy to integrate in your ERP

The L-mobile machine data collection system offers standard interfaces for all common ERP systems.

proALPHA MS Dynamics Other ERP systems

Production and machine data collection for proALPHA

Seamless and automated recording of machine data linked with proALPHA

Networked and automated manufacturing is increasingly important. Companies need to record data in real time seamlessly and without errors. Running machine and production data collection connected to proALPHA not only gives you valuable data, you also get the conditions needed to increase your production performance. Directly linking L-mobile machine data collection to proALPHA facilitates continual, precise recording of your machine-generated data.

The machine data collection solution for proALPHA ensures high data transparency in your manufacturing. Automated recording of production data provides precise documentation and automatic postings of events that occur during the manufacturing process. Besides the reported production data from your employees via L-mobile production data collection, L-mobile machine data collection also provides you with process data for optimizing your production processes.

How the integration in proALPHA works

The machine signals are first evaluated according to their significance within L-mobile machine data collection and where possible, posted to the corresponding production order in proALPHA. Production data from L-mobile production data collection is sent to directly to proALPHA after it is recorded. By storing your recorded data at L-mobile, you get a failproof system so that all manufacturing processes will continue to operate, even if the connection to proALPHA is interrupted.

The L-mobile SCADA-Server then functions as the central database between L-mobile and proALPHA, and is used for processing, interpreting, and storing the recorded data. This allows for the evaluation and analysis of signal data (e.g. machine malfunctions and process data, such as pressure, temperature, or flow values) together with data from proALPHA. The interaction between machine data collection, the SCADA server, and proALPHA makes it possible to receive signal data directly from the machine and perfect your workflows through continuous process improvements. The goal of the digitalization process is to maximally optimize manufacturing and logistics processes, thus making your company in fit for the future.

L-mobile digital production – Identify malfunctions early on by using a machine data collection software

The machine monitoring system: Live visualization of your production data

L-mobile Digitalisierte Produktion - Datenerfassung BDE Cockpit

The machine monitoring system can be used as a further addition to your proALPHA ERP system. The cockpit provides a visualization of manufacturing data in real time, making machine statuses and any malfunctions visible at a glance. The display of actual and target data of production quantities, deadlines, and goods and scrap quantities gives you a continual overview of your manufacturing processes.

Machine data collection for MS Dynamics NAV and Business Central

In the manufacturing industry, it is especially important to continually optimize production processes and effectively utilize machines and production lines. Machine data collection for MS Dynamics NAV and Business Central gives you an ideal basis for leveraging manufacturing-specific real-time data to create sustainable optimizations of your manufacturing processes. Connecting your machines and production lines with technology ensures reliable recording and processing of the data that is generated during manufacturing processes.

The machine data is reported back directly to your Microsoft Dynamics ERP system, either via a Scada Server or an IoT platform. All recorded production data from machine data collection for MS Dynamics NAV und Business Central is then displayed in an easy-to-read visualization in the productivity cockpit. You stay fully informed at all times about the current production status, thanks to the overview of machine statuses, malfunctions, output quantities, and deadlines.

Potential uses of machine data collection software for NAV and Microsoft Dynamics 365 Business Central

L-mobile Digitalisierte Produktion - Einsatz der MDE-Lösung als Frühwarnsystem in Lebensmittelbranche, Kunststoffverarbeitung, Automotive Branche

The built-in early warning system in the machine data collection software for Microsoft Dynamics 365 and Navision makes it possible to quickly detect deviations in production steps and initiate appropriate measures. The machine data collection system is especially useful for industries subject to strict regulations or which process sensitive materials to produce error-free products. For example, in the food industry, an interruption in the cold chain or deviations from ingredient combinations must be avoided entirely. Likewise, companies in plastics processing, the automobile industry, and serial manufacturers use the machine data collection solution for Microsoft Dynamics 365 and Navision to achieve reliable monitoring and evaluation of machine data in real time.

Connecting machine data collection to your ERP system

Our software solution offers standard interfaces for all common ERP systems. Don’t see yours listed? Feel free to contact us.

Digital production events

Would you like to experience digital production firsthand? We cordially invite you attend one of our multi-faceted, real-work-world events on Industry 4.0.

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Digital production references

Fritz Stiefel Industrie-Vertretungen GmbH

L-mobile case study: Digital warehouse management, warehouse ready for Infor COM, Mack Alu-Systeme GmbH

FoamPartner Germany GmbH - Recticel En