J2com Ltd. - CNC, DNC and CAD/CAM software

MDC-Max

OVERVIEW
DATA COLLECTION
MONITORING / ANDON
REPORTING
NETWORK OPTIONS
ALL FEATURES

Manufacturing Data Collection and Monitoring

Collect data from your shop floor in real-time to discover and eliminate production bottlenecks, optimise resource utilisation and streamline processes.

The complete MDC solution

MDC-Max enables you to collect and analyse data from machines and operators to get real-time and historic insights into your shop floor's productivity, performance and quality.

MDC-Max lets you use the data in various ways and on different platforms. You can show the data on information screens throughout the shop floor and offices to keep everyone updated and motivated - or send the data to external systems, such as ERP or MES, for further analysis and integration.

Benefits

Improved efficiency

Understand the performance of equipment and personnel with real-time data collection. Eliminate production bottlenecks and optimise resource utilisation.

Accurate data collection

Eliminate manual, time consuming and often inaccurate data collection by automating and streamlining the entire data collection process.

Faster response times

Monitor and visualise the performance of equipment and personnel to respond faster, catch errors sooner, and communicate better.

Eliminate guesswork

Understand the inner workings of your production with customised reports including machine downtime, OEE and other essential KPIs.

Reduce administration time

Reduce paper reliance and administrative time. Update your ERP, MES or other administrative system with real-time data from equipment and personnel.

Access your data anywhere

Access data from one or more sites directly from your mobile device. Easily check the status of equipment or any other information critical to your operation.

Features

Real-time monitoring / Andon

See the current status and performance data of your machines on Andon boards, PC and mobile. Customise the layout and content of screens to suit your needs.

Customisable reports

Supports both standard and specialised network protocols to communicate with most manufacturing equipment. Mazak, Deckel, Agie, Fagor, Brother, Modbus, and many more.

Real-time reporting

Generate real-time reports that dynamically update as data comes in, such as machine timelines.

Works with your equipment

Collect data automatically or manually using your existing wireless network, Ethernet, RS-232 or Parallel I/O. Use existing barcode readers and PCs on the shopfloor.

Integration with external systems

Streamline data management and workflows by updating ERP, MES or other administrative systems directly with data from MDC-Max.

Operator interface (manual collection)

Enables operators to access essential information directly at the machine and enter data such as current shift, job, reasons for downtime and scrap.

Andon and signaling units

Control signaling units such as stack lights, buzzers and Andon boards that indicate the status of your machines.

Email and text notifications

MDC-Max can send text and email alerts to key staff on any machine and operator event such as automatically during unattended runs.

Secure user management

Fine-grained control over user access and permissions. View logs of user actions and system events for auditing and troubleshooting purposes.

Data Collection

While data from machines can be collected automatically, error-free and unattended, the manual data from personnel provides the context to fully understand downtime, scrap and other factors affecting production negatively.

COLLECTION TYPES

Automatic data collection

Machine data is collected automatically and unattended through a network. When a machine event occurs, such as starting or stopping, the signals associated with those events are sent to MDC-Max, stored and processed for further use.

Manual data collection

Operator data provides the context needed to fully understand reasons for downtime, scrap or other negative factors. For manual data collection, MDC-Max provides an operator interface for PC and mobile devices. It also comes with full support for barcode readers.

INTERFACES

Operator Screen

Enables operators to access vital information and enter reasons for downtime, scrap, current job/operator/shift, and more. Can be customised and accessed with a mobile device or PC. One device can manage several machine-specific Operator Screens. Operator tablets can also be mounted at every machine.

Barcode readers

Enables operators to scan a barcode to provide reasons for downtime, scrap, current job/operator/shift, and more. MDC-Max can generate and print barcodes. Mostly relevant if barcode readers are already available. Otherwise, we recommend using Operator Screens.

INITIAL SETUP

Start small

More data does not always equal more value and an MDC system always requires new workflows and training. The best way to succeed, is to start small and get the easy benefits by analysing only three to five data points. With more experience, the system can be expanded. See examples below for inspiration.

1. Production vs. downtime

This solution gives data about the production or downtime of a machine. Data is collected automatically from the machine, so a supervisor needs to ask the operator the reason for the machine stoppage to get more information.

2. Downtimes in more detail

This solution accurately shows a machine's efficiency on every job. We can show the total downtime percentage for each type of stoppage such as Tooling, Setting, Maintenance, etc. The operator enters the reasons for downtime using an Operator Screen or a barcode reader which can then help identify the exact causes of production loss.

EXAMPLE

Elements in a setup

The following diagram shows a simplified MDC setup with data collection from machines and operators.

Machine signals and operator feedback are sent to MDC-Max through the local network using wireless and Ethernet.

Each machine has a tablet with the Operator Screen application or a barcode reader to provide data. An operator has a smartphone where he can provide data about any machine in the setup. He just opens the Operator Screen on his phone for the specific machine he is at.

A legacy machine has been connected with a serial connection to the Ethernet network (and some internal wiring) to track start and stop signals.

Real-time Monitoring / Andon

Machine and operator data can be visualised in real time on Andon boards and digital signage on the shop floor and office areas. Data can also be accessed remotely via any modern mobile device such as a smartphone or tablet.

ANDON BOARDS

Live Screens

Machines are listed and colored to indicate state along with information such as cycle time, current job/operator/shift, parts, OEE, and more. Fully customisable and accessible on mobile, tablet, PC and smart TV.

Dashboards

Dashboards are composed of data blocks such as Bar graph, Pie chart, Value list, Gauge, and more. Focus on different facilities, machine groups, and so on. Fully customisable and accessible on mobile, tablet, PC and smart TV.

Shop Floor Screens

See the status of machines based on their location. Colors indicate state along with small alerts for additional status. Select a machine to view details. Fully customisable and accessible on mobile, tablet, PC and smart TV.

Slideshows

Combine Live Screens, Dashboards and Shop Floor Screens into Slideshows for information screens. Options include auto-scroll, pause and resume. Fully customisable and accessible on mobile, tablet, PC and smart TV.

ANDON UNITS

Stack lights, Buzzers, and more

Configure data events to control stack lights, beacons, buzzers, sound alarms and other Andon units for visual and audible feedback of machine state. A unit can be shared by a group of machines if needed.

UNATTENDED

Notifications and Lights-out monitoring

Notifications can be sent on any event. If machines are running unattended and one falls behind or stops, a stand-by operator can be notified promptly via text or email. Or a machine that is out of units to process and automatically notifies a nearby operator.

Reporting

Real-time and historic reports can be generated and viewed directly in MDC-Max or exported to Microsoft Excel. MDC-Max can also keep Excel sheets up-to-date or send data to external applications.

Reports

CUSTOM REPORTS

MDC-Max can generate custom real-time and historic reports from the data it collects. Data can be presented as tables, pie or bar charts, and production targets, work shifts, KPIs, and more can be included. You can also generate different Event logs such as by operator, machine, and job to check how each machine and operator is doing. Examples of other reports:

Cycle time per part (min, max and average)
Number of parts per shift/operator
Number of scrapped parts
Machine downtime
Scheduled maintenance
Unscheduled maintenance
Setup time per part
Operator effectiveness
Overall Equipment Effectiveness (OEE)
Mean time between failures (MTBF)
Mean time to repair (MTTR)

EXAMPLES

Cycle time, duration and deviation

For each part in a job we can see the cycle start and stop times, duration and deviation (%) from the planned cycle time.

Machine utilisation as timeline

Each timeline shows the exact machine status during the selected time frame and dynamically update at a set interval to include new data.

Productivity summary chart

Summarised utilisation in percent and visualised as Pie charts. Makes it easy to see how each machine is doing.

Machine utilisation with target

Bar chart showing machine utilisation in percent over a 24 hour time period. Target and Minimum values added.

Daily overview

Overview of utilisation for several machines and downtime as a percentage of the total shift time.

Microsoft Excel

STAND-ALONE REPORTS IN EXCEL

Stand-alone reports provides a direct and convenient way for authorised users to access and update MDC-data in Excel reports without using MDC-Max. Reports can take advantage of all the built-in functionality that Excel has to offer such as Column-, Line-, Pie-, and Bar Charts. Once a report is configured, Excel provides the flexibility to filter data by machine(s), operator(s), time period, and more.

EXPORT REPORT DATA TO EXCEL

MDC-Max can also export the data of any configured report to Excel. This enables you to generate and view reports in MDC-Max and export the same data for further analysis in Excel.

Site Dashboard

Detailed Setup Dashboard

Andon Report

Export reports to Word or PDF

Integration

MDC-Max provides several ways to automate processes and exchange data with a company's existing software systems such as an MRP, ERP or MES.

Transfer data to external systems

On specific events or conditions, MDC-Max can transfer or update data in external data sources such as a database or web service. Data can also be exported and transfered in several formats such as XML and JSON.

External access to database

MDC-Max can authorise external systems to pull data directly from its database (read/write/update). Can normally be configured using the standard Open Database Connectivity API (ODBC).

Further integration and automation

MDC-Max also provides the OEMLink C++ library which can be programmed to "catch" incomming data events and trigger custom code to call a web service, export data, call up external APIs, and more

Network options

MDC-Max can be installed on your existing network and supports a variety of protocols and hardware options including serial wiring, Ethernet and wireless networking.

Connections

MDC-Max uses a network to establish connections and collect data from equipment. Often a company's exiting local network is used, but in some cases a dedicated, closed network is preferred. Depending on the machines' data collection capabilities, different approaches are possible.

Direct connection

If a data interface is available on the machine (see table below), it can often be connected to a network via an Ethernet cable. No additional hardware is required beyond optional devices for operator input such as a mounted tablet. However, if the interface is disabled on the machine control, it can be costly to activate. In this case, a Hardware connection might be preferred.

Hardware connection

If no interface is available, a technician can "pull" signals from the machine using a combination of internal wiring to PLC relays and devices such as an MDC-Box or the Moxa ioLogik. These devices manage the connection between the machine and network, and facilitate signal transmission to MDC-Max.

Supported controls

For direct connections, MDC-Max supports a wide variety of machine controls. The following are some of the most common, but many more are supported. If your control is not listed, please contact us for more information. We are continuously adding support for new machines.

Control	Required interface	Extent of data access
Fanuc	FOCAS	Full compatibility
Haas	M-Net	Full compatibility
Mazak	MTConnect	Full compatibility
Okuma	MTConnect	Full compatibility
Mitsubishi	MTConnect	Full compatibility
NUM	MTConnect	Full compatibility
Heidenhain	DNC Opt #18	Full compatibility
Siemens (840D, 810D)	Hardware adapter	Most compatibility

ALL FEATURES

System components

Scalable architecture / multiple plant support

MDC-Max is a versatile solution that can suit both small shops and large enterprises with thousands of machines across multiple locations. It consists of Server, PC client and Web Client components that can run on one PC or multiple servers with unlimited PCs and Web Clients connected.

CIMCO MDC-Max Server

Server application that runs a fast SQL database (optionally Microsoft SQL) and handles various tasks in the background, such as processing incoming data, updating reports, communicating with external systems and distributing monitoring data to Dashboards, Live Screens, Operator Screens, etc.

CIMCO MDC-Max PC Client

Windows-based PC client application that allows configuring the MDC-Max system. The PC client also shows Timelines, Live Screens, Operator Screens and offers advanced reporting features.

CIMCO MDC-Max Web Client (mobile client / mobile monitoring)

Web client that works on any modern mobile device, such as tablet, smartphone or smart TV. Allows remote access to Operator Screens, Dashboards, Live Screens and Shop Floor Screens. Data is updated in real-time without browser-reloading and all clients can be updated centrally. Supports bright and dark themes.

CIMCO DNC-Max (machine communication)

Software for configuring machine ports and managing network. Also offers features such as advanced program transfers, Remote Request, dynamic feedrate and spindle speed adjustment, auto-receive, parameter offsets and more.

Data collection

CIMCO MDC-Max tracks both scheduled and unscheduled downtime by combining machine and operator data. While machine data can be collected accurately, error-free and unattended, operator data provides the context to fully understand reasons for downtime, scrap or other aspects that impact production negatively.

Automatic data collection

Accurate data from machines is collected automatically and unattended by MDC-Max. Most installations will, as a minimum, collect data on Cycle Start, Cycle Stop, and Part Complete. The data collection events can be customised according to the monitoring capabilities of each machine.

Manual data collection

MDC-Max offers an easy-to-use operator interface for mobile and PC to view and enter data manually. Operators can register the exact causes of machine downtime such as Setup, Maintenance, Scrap, Inspection and more. MDC-Max also supports barcode readers.

Unlimited data collection events

MDC-Max can be configured to collect data on any event limited only by machine capabilities.

Real-time monitoring / Andon boards / digital signage

Machine Timelines

Real-time monitoring using Timeline charts enables you to easily monitor the current and past state of all your machines. Each machine state and downtime reason is visualised with different bar colors and can be expanded to reveal additional information.