Summary
Key results
Real-time monitoring and visualization of production processes
Better identification of deviations and minimization of downtime
Increasing control over production processes
In the aerospace industry, repeatability, quality, and process control at every stage of machining are critical, and any downtime or parameter deviation can mean huge financial losses and the risk of non-compliance with quality standards.
At the client’s Mielec plant, part of the machine park was already connected to CyberVision, but additional machines still remained outside the shared monitoring system, and some data was collected manually in Excel files. This made it difficult to quickly determine the actual machine workload across the entire plant and identify where downtime was occurring.
The client’s goal was to improve efficiency through machine monitoring and the use of current data for business decision-making. Extending CyberVision to additional workstations was intended to provide a more complete picture of plant operations and shorten response time to irregularities. To deliver this scope, the client chose Sii, which supported the project in the areas of automation and communication between the machines and the monitoring system.
CyberVision extension and interface personalization
The goal of the project was to extend the operating CyberVision solution, specifically the CNC Tracker module, to 3 additional machines. Sii engaged 1 expert in the role of Automation Engineer, who carried out the work in parallel with ongoing production and was responsible for enabling communication between the new workstations and the system server.
The scope of work included:
- Extending the network infrastructure to 3 additional machines – expanding monitoring to new workstations
- Configuring S7 protocol communication between the machines’ programmable logic controller (PLC) controllers and the server – enabling data transmission to CyberVision
- Verifying connectivity options with the machines on the manufacturer’s side – removing technical limitations at the implementation stage
- Testing correctness of operation – confirming proper data collection from the new machines
After launch, the solution displayed the machine status in real time – operation, downtime, changeover, or failure – as well as unit counts and operating time. The data was available remotely and historically, giving operators, the planner, managers, and the board a single point of view into the operation of the new workstations.
Full control over the process and real-time data
The CyberVision extension gave the client a more complete view of machine workload in the plant and shortened response time to failures. Instead of analyzing fragmented data, teams could check workstation status on an ongoing basis and identify downtime points more quickly.
The project also had strategic importance. Unified data from additional machines created the foundation for further development of production monitoring, historical analysis, and measurement of Overall Equipment Effectiveness (OEE). In practice, this means better preparation of the plant for the next stages of development in line with the Industry 4.0 approach.