Extracting data from machines 

IT systems for production plants should whenever possible be based on data coming directly from machines, sensors or actuators. What distinguishes the Explitia team is its unique combination of competences. Thanks to this, we are able to offer a comprehensive implementation of IT solutions – from analyzing real needs, creating an implementation roadmap, to extracting data from machines, implementing an IT system and the post-completion support.

Extracting data from machines – where to start?

 The analysis of current processes should be the starting point for the implementation of an IT system. Therefore, in the first stage, we always conduct a pre-construction audit (and we start work with a workshop – see our work process). Thanks to this, we can determine the real challenges of the production plant. Then we create a system implementation a roadmap and a plan to obtain data directly from the sources.  

Data Acquisition from New Machines

The information system integrator and the client often face limited capabilities when it comes to acquiring data from new machines and devices. Interfering with software structures, though sometimes necessary for data acquisition, is impossible due to warranty safeguards. It is, therefore, advisable to anticipate the need for integrating the machine control system during the software development phase by the supplier.

Data sources

It is not uncommon that the work on obtaining data directly from sources is a typical engineering activity. They involve analyzing software and electrical documentation, finding appropriate signals and their sources. Additionally, they aim to diagnose in which spaces the IT system may have difficulties in the future because the measurement does not exist at the moment or is not very accurate..  

To obtain a fully automatic system, it is necessary to extract data from: 

  • PLC controllers, 
  • sensors, 
  • other IT systems, e.g. ERP, 
  • in an electrical way. 

If the data necessary for performing required functions does not come from a single type of source, it is essential to develop a plan that allows for the integration of data from multiple sources into a single standardized model. This creates a kind of intermediary layer between different sources and the information system. Often, it is possible to leverage a common communication standard for all systems, but at times, a bespoke solution may need to be developed in this regard.

Obtaining data from machines – Client or Supplier

The client can obtain data on his own by building an internal team of specialists or use the experience and knowledge of explitia team. Separating this scope of work outside the company has many benefits, including:  

  • Correctness guarantee – the external team has many years of experience and knows perfectly how to correctly obtain data from machines, 
  • Interdisciplinary of the team – thanks to which data is obtained in an optimal way. 
  • Cost-effectiveness. 

Do you always have to automate?

A thorough analysis allows you to determine which processes are really worth automating and which should be reconsidered. It may turn out that in individual cases automation has no business justification – its advantages are small and the costs outweigh the benefits. In such a case, a decision is made if this value should be entered manually and where it can be entered manually. explitia’s systems have the ability to build forms for manual data entering 

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Do you want to move your production plant to level 4.0? Are you interested in modern solutions for industry in the field of automation and digitisation? Be sure to let us know!

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