Intelligent Machine Data Acquisition

Solutions

01 Description

Manufacturing companies that do not yet collect, store, and analyze their machine data can use Machine Insight Services software to network their machines and collect order and process data. This software optimizes production by managing and centrally controlling the manufacturing machines and monitoring the process data generated during production in real time.

The visual representation of the parameters makes them easier to grasp and understand at a glance. Our software creates the data basis for reliable predictive maintenance.

If each component has a unique number, the machine data can be clearly assigned to that part and saved. This speeds up complaint processing, because with just one click you can see the entire component history, including batch tracking.

We offer seamless integration into your existing systems and complete data security within your network.

One of our strengths is the implementation of customized solutions. We would be happy to discuss your specific application with you in person.

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02 Your benefits

Faster changeovers and fewer input errors

Standardized processes and centralized specifications shorten setup times and reduce manual input errors.

Your overall equipment effectiveness (OEE) increases

More stable processes, fewer interruptions, and higher quality will measurably improve your OEE.

Your downtime decreases

Deviations are detected early on, allowing you to intervene before the system comes to a standstill.

Signs of wear are detected at an early stage

Trends in process and machine data reveal wear and tear before damage occurs.

Reduction of high repair costs

Predictive maintenance and servicing enable preventive measures instead of emergency repairs, thereby reducing spare parts, service, and downtime costs.

Comprehensive analysis of your manufacturing process

All relevant process data is continuously recorded, correlated, and evaluated transparently.

Reliable traceability of your components and batches

Part- and batch-related histories enable quick clarification of causes in the event of complaints and audits.

03 How it works

The software runs on your network on-edge or on-premise, so that the data generated remains with you. Alternatively, the data can also be stored with a cloud provider. We can connect your machines via standardized interfaces such as OPC UA, and other interfaces are also supported.

We also offer retrofit solutions. A gateway enables older machines to be integrated into our modern software platform. These settings are then processed and fed back to the respective machine according to your specifications. This reduces setup times and minimizes repeated manual entries. Once the machines are equipped with all components, production starts automatically.

Machine Insight Services allows multiple machines to be operated in parallel and remotely directly on the computer or mobile device without manual selection on the local HMI.

The application provides interfaces for your existing systems. These allow you to connect your systems, such as ERP or MES, and your control station to Machine Insight Services. Your order data can then be sent to the machines. The machines report the process data of the manufactured parts, which is evaluated in real time using artificial intelligence, stored, and prepared for anomaly detection and predictive maintenance. The AI models monitor production, flag any anomalies, and automatically report when a machine or tool needs maintenance.

Would you like to digitize your production and make targeted use of your machine data? We will show you our solution.

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04 FAQ

1. What exactly does the retrofit solution look like and how is the gateway implemented?

Our solution is based on proven hardware components that we provide in collaboration with established partners.

The selection and integration of suitable gateway and hardware solutions is project-specific and based on the existing machines and systems. We remain your central point of contact throughout the entire project and coordinate all partners involved on your behalf.

2. What other interfaces are supported besides OPC UA?

In addition to OPC UA, we support Modbus, Beckhoff, Schneider Electric Modicon, Siemens SIMATIC, Profinet, Profibus, IO-Link, MQTT, REST, and HTTPS, among others.

Upon request, additional interfaces can be integrated to ensure optimal connectivity to your existing system landscape.

3. Where exactly is AI used in your solution?

The software uses artificial intelligence to evaluate the data obtained in real time. This data is stored and visualized, revealing anomalies that can then be analyzed.

Numerous process parameters are monitored simultaneously in the plants. Each parameter may be within the permitted range on its own, but when combined, they can create a critical constellation that leads to quality problems or malfunctions. Above a certain number of influencing factors, such patterns are difficult for humans to reliably identify, as the cause-and-effect relationships are no longer linear and can no longer be understood intuitively.

This is where AI comes into play in our solution. It does not consider parameters in isolation, but rather in combination, recognizing unusual patterns early on and automatically flagging or reporting them. This enables timely warnings, targeted root cause analysis, and preventive intervention before scrap is generated or the plant comes to a standstill.

4. How does your solution differ from the machine manufacturer’s software?

Our solution for digitized production is manufacturer- and platform-independent. It enables the networking and evaluation of machines from different manufacturers within a common system landscape.

Unlike manufacturer-specific software, which is usually limited to individual machines or closed ecosystems, we create comprehensive transparency across your entire production process.

This allows data to be centrally collated, analyzed, and used for optimization purposes—regardless of the manufacturer of the machines.

MACHINE
INSIGHT
SERVICES

Markus Müller

Business Development Manager

sales@kurzdigital.com

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