Boost Your

Production
Efficiency
IIoT and AI industrial solutions
Case Study
in Discrete Manufacturing

Managers sees manufacturing site as a “black box”

Nobody really has an overview of what is really happening on the shop

floor

Every customer wants to calculate OEE

Though, not many understand how to do it.

Majority seeks on-time notification service about

different events on the manufacturing site

Signal towers are good, but not fully solve the task

|2
MDCplus Holding

Corporate Headquarters ▪ Implementation of MDC (Machine

Data Collection) systems for
Holdings, Corporations, Concerns,
Territory spread enterprises and
their manufacturing subdivisions
▪ Connection to any machine type
(CNC, PLC, Furnaces, Robots,
Painting shops), any vendor and
any year of manufacturing
▪ Real-time Enterprise data that was
stored on the local Customer’s
server (protected corporate server):
equipment performance and OEE,
operator performance & meeting
KPIs , number of produced orders,
energy consumption, number of
scraps etc

Manufacturing units and workshops Corporate headquarters

|3
Zyfra Entrepreneurial Company of the Year in
the AI-based Solutions for Process
Industries

270+ 7
enterprises offices “THE DIGITAL ADVISOR FOR TUBE THERMOPROCESSING”

WAS AWARDED TOP-10 BEST

14 000 400+ USE CASE AT IOTWC2018 IN BARCELONA

equipment units employees

Member of MTConnect Institute
connected
Member of Industrial Internet Consortium

$30MLN 25 Resellers and service partners in

Global Revenue digital twins
India, China, Singapore, South
Korea,
France, Germany, Russia, Finland

Peru, Chile, Vietnam,

#1 in digital
Romania, Ukraine
manufacturing*
*mediaindex
Industries
1 2 3
Mining Metals Discrete
Manufacturing

Oil&Gas Chemicals

4 5
Zyfra’s World Presence

Finland, Russia, Bulgaria,

Romania, Ukraine, Kazakhstan,
Belarus More than 250
Customers Selling AI for China
steelmakers
China, Singapore, Taiwan,
5 projects in Morocco
South Korea, Malaysia (
10 projects)

Ongoing project
2 project for VIST in
in ME for O&G
India.
platform
20 projects for MDCplus
in India (>100 machines)

2 Projects in
LATAM

1 Ongoing project

- ZYFRA has a presence in regions - VIST Mining Automation Solutions

(Local office or partnership channel)
- Industrial equipment machine data collection

- Focused Regions 2019-2020 - AI solutions

|6
MDCplus – Real-Time Machine Data
Collection System
Russian, French, English and Chinese
Main versions

4 more languages are on the way (including German, Italian,

Spanish)

MDCplus functionality is “best in class”

10 resellers in Indian

8 000 connected machines

4 software releases
(per year)

100+ employees

|7
What are MDC, MES and ERP?

ERP system monitors the

whole enterprise including the
Enterprise Resource
business part of the enterprise Planning (ERP)
ERP

MES monitors the whole Manufacturing

manufacturing part of an
enterprise Execution System
(MES)
MES
MDC system collects data Machine Data
from industrial Collection (MDC)
equipment

MDC

|8
MDCplus improves overall machine
utilization
Before MDCplus After MDCplus
Implementation of MDCplus allows to:
▪ Increase machine utilization from
10 to 30 %
33%
▪ Improve job planning and quoting
13% accuracy
▪ Reduce Energy Consumption
65% ▪ Calculate OEE with accordance to
34% ISO22400.
15%

22%
The Return Of Investment (ROI)
7%
11% period on average is 3 months.

The exact ROI for the project you can

working on cycle working on cycle calculate here:
machine is off machine is off https://mdc-plus.com/roi-calculator/
unreasonable downtime setup time
other other

|9
Zyfra MDCplus features

Vibration
Computerized Production Monitoring and
Monitoring Maintenance Monitoring Diagnostics

API connection for external

ERP, CAD/CAM/PDM, MES NC Program
and BI systems management Mobile app Video Monitoring

| 10
How does Zyfra MDCplus work?

| 11
MDCplus hardware

▪ HMI Operator touch monitor

▪ Monitoring terminal
▪ MDC Adapters
▪ Barcode scanner
▪ RFID reader
▪ Interactive kiosk
▪ Serial Wi-Fi Adapter - RS232
▪ Xbee module
▪ Current sensor
▪ Vibration sensor

| 12
Mobile monitoring in the Cloud

| 13
CMP - Modern tool for a workplace analytics
based on mobile and tablet devices

Brand new interface with

smartphone access

▪ Multilingual interface
▪ Cross platform
▪ Adaptive Interface(under
development)
▪ Personal cabinet for operator
▪ Downtime reasons calculation
▪ Shift tasks
▪ Working with NC Programs
▪ CMMS (MRO)
▪ 1 CPM per several machines
▪ Supports laptops or automated
workplace's

| 14
Monitoring dashboard for TV

New interface for a TV

screens

▪ Multilingual interface
▪ Cross platform
▪ KEY KPI’s
▪ Additional dashboards by
request

| 15
MDCplus Kit

Ready-to-use “out of the box”

hardware kit

▪ Monitoring Terminal TVV-10

▪ Barcode Scanner
▪ MDC Unit R-03D
▪ ADC/DC Clamp TK-3 - 3 pcs.
▪ Mounting Kit МК-1
▪ Mounting Bracket for TVV-10
▪ Connecting Wires

| 16
Simple connection to any kind of machine

Operator can use a tablet for a downtime reasons

entries or NC program uploading. Table is
mounted in front of the machine tool and
connected by wireless\lan to MDCplus KIT. CPM
module installed on Tablet

MDCplus Kit is installed near machine tools. Device is

used to grab data from the equipment (maybe from
several machines) and to transmit data to server. TVV-
20 can grab data directly from CNC or from different
sensors (current, vibration, temperatures etc.) that can
be connected to the machine tools.
| 17
Collective Monitoring Panel for Manual
Workstation (Current POC) as additional added
value of MDCplus solution
MDCplus kit supports all tablets that can be installed
in 1 workshop\room – transmits all required data to
the server. In case of network failures with a central
server, TVV-20 can store all the data inside of it’s
memory core and would be transmitted after the
connection is established again.

Workplaces can de digitalized with the help of

our CPM module. Operator enters shift, tasks,
measurements start\end that will be
transferred to the system directly
Operator uses a tablet with CPM Module which
is mounted to the workplace and connected
wirelessly\lan to the MDCplus Kit.

| 18
Collective Monitoring Panel & Group of
Machines

Operators can use tablet for a downtime reasons entries

or NC program uploading. Tablet is mounted in front of
the machine tool and connected by wireless\lan to
MDCplus KIT. CPM software module will be installed to
the tablet.

Zyfra can provide tablets & special holders for them

alongside with the MDCplus software & hardware kits.
This solution can be used as a special zone for different
MDCplus KIT can be mounted in a workshop specific zone. It is operators.
used to get the data from the several number of CNC machines.
TVV-20 transmits data to the server. TVV-20 can grab data
directly from CNC or from different sensors (current, vibration,
temperatures etc.) that can be connected to the machine tools.

| 19
Collective Monitoring Panel & Automotive
line

Operator is using CMP & tablet to enter dowtime reasons, count

equipment efficiency, request & assign tasks for service &
maintenance teams. Data from the line can be transmitted by
MDCplus KIT

| 20
MDCplus software (Client/Server)

| 21
Functionality

Machine Data Production Downtime Digital

COLLECTION OPTIMIZATION MANAGEMENT MANUFACTURING

Automatic / manual data
collection
Use the existing network to
monitor CNC machines, robots,
PLCs
Display machine status on large
TV screens, PCs, mobile devices
Machine-based job scheduling
improves utilization and
production flow
Creation and configuration
of new orders
100+ KPIs and Metrics
Customizable Reports and
Charts
Unlimited number of data
collection events
Track reasons for machine
downtime
Reduce unscheduled downtime
EMAIL & SMS messaging
Computerized maintenance
management system
Paperless production
Include all machine tools and
employees in the same
network
Assign and transfer jobs and
NC programs to the machine
ERP and MES integrations
Predictive Maintenance

| 22
 Monitoring module

Features

▪ Equipment statuses and downtime reasons in real time

▪ CNC control’s parameters (speed and feeds, coordinates, load, etc.)
▪ Set up controlled events and notifications for appropriate company units (Email, SMS)
▪ Generate reports and send them automatically according to a set schedule
▪ Display Performance Dashboard on a TV panel and basic reports on mobile devices
▪ Analyze trends in equipment and staff performance
▪ Calculate key performance indicators (KPIs) of the equipment and staff, including OEE

| 23
 Monitoring module

24 | 24
Analytics

▪ 100+ Report and Graph templates ▪ Number of scrapped parts

▪ Report generator ▪ Scheduled Maintenance
▪ Overall Equipment Effectiveness ▪ Unscheduled maintenance
▪ Cycle Time per Part ▪ Setup Time per part
▪ Number of parts per shift / operator ▪ Operator effectiveness

| 25
 Analytics

26 | 26
 Production Monitoring module

Features

▪ Part counter & scrap control

▪ Management of time for technological operations
▪ Machine-based job scheduling: shift tasks, routing sheets and orders
▪ Generate reports and calculate KPIs, including OEE

| 27
 Production Monitoring module

28 | 28
 CNC Program Management Module

Features

▪ Reliable and efficient CNC communication and NC program lifecycle management

▪ Storage of NC programs
▪ DNC Communication (Ethernet, USB, RS-232)
▪ Analyze NC program usage and compare it with the reference NC program

| 29
 CNC Program Management Module

30 | 30
 Vibration Monitoring and Diagnostics
module
Features

Measurement of the overall vibration level, analysis of threshold values, detection of impacts.
Requires sensors and a vibration controller (SKF or IFM).

| 31
 Vibration Monitoring and Diagnostics module

32 | 32
 Maintenance Management Module (CMMS)

Features

▪ Dispatch non-scheduled (emergency) repair and maintenance

▪ Schedule MRO operations based on working hours and actual states of the CNC machine
▪ Control execution of scheduled repairs
▪ Manage and record the work of maintenance and repair staff
▪ Manage procurement for maintenance and repair services
▪ Documentation support of maintenance and repair operations
▪ Interaction with external service providers

| 33
 Maintenance Management Module (CMMS)

34 | 34
Equipment Condition Predictive Diagnostics

PREDICTIVE DIAGNOSTICS METHODS FEATURES PREDICTIVE DIAGNOSTICS METHODS

• Use machine learning methods, which allow to take

into account various nonlinearities in mechanic Diagnostics based on Diagnostics based on normal
equipment operation historical failures mode

• Use multiple sources of information (Do not High accuracy of failure Along with generating
prediction signalizations, enables assembly
substitute classic diagnostic aids, but supplement unit diagnostics
them)
Does not require availability of
historical failures
• Allow to take into account not only mechanical
characteristics but also their interconnection with
production process Requires large number of In the absence of failures can
recurrent failures give false activations
Not always takes into
consideration cause-effect
relations

| 35
 Diagnostics based on historical failures
DESCRIPTION OF APPROACH PRINCIPLE
Failure events Based on data on
equipment unit
Inoperable
condition operation and failure
statistics, a
mathematical model
NECESSARY DATA
Jan Febr March Apr May June July is built, which model
Failure determines failure
probability, % Mathematical model indicators •Data on equipment unit operation, related
probability at the time
100
production process and failure statistics
point To build mathematical model
50
It is desirable to have at least 3 recurrent failures
0
Jan Febr March Apr May June July
On a real-time basis, •Production process flowcharts
Failure
Flowcharts from APCS / MES - for top-level understanding of
probability, %
Failure limit Forecast failure probability is equipment unit interconnection with other units and place of
100
calculated according to the unit in production process
Signalization limit
50
Actual
the obtained model
0 In case when threshold •Equipment unit certificate and production
Aug Sept Oct Nov has been achieved procedures
Current Forecast date
Date of
signalization date of failure signalization is generated,
generation start and forecast date of
failure is calculated
| 36
 Diagnostics based on normal mode of
operation
DESCRIPTION OF APPROACH PRINCIPLE
Compressor
Inoperable condition of
equipment unit model
Based on data on normal
speed, rpm operation of equipment
unit, mathematical model
Operational condition is built, which model
lower limit defines key indicators, by
Bearing which equipment
temperature,
Model
condition monitoring is NECESSARY DATA
deg. C
Actual implemented
•Data on equipment unit operation in normal
mode
To build mathematical model used as reference for comparison
On a real-time basis, key
High-high limit of signalization
3.5 indicators are calculated
2
High limit of signalization
according to the obtained
•Production process flowcharts
Flowcharts from APCS / MES - for top-level understanding of
model.
0 equipment unit interconnection with other units and place of
In case of significant deviation the unit in production process
-2
Lower limit of signalization
of actual values from model
-3.5 ones, signalization is
Low-low limit of signalization •Equipment unit general arrangement
generated
drawings
To determine design features and interconnections between
Date of signalization Forecast date
start Current date of failure
multicomponent assemblies

| 37
Economic Effect from Predictive
Diagnostics Implementation
The defect is
The economic effect may be based on: identified by
standard
diagnostics tools Equipment unit The unit has been put into
failure operation after repairing Before
Potential for reduction
Reduction of unscheduled shutdown time
Due to earlier defect identification and executing preliminaries in order to reduce
stop repair
Preparatory operations prior to Repair operations
repair (e.g., ordering spare parts)

The defect has

been identified
by predictive Equipment unit The unit has been put into
Reduction of losses during changeover to backup diagnostics tools failure operation after repairing
Now
equipment
For example, changeover requires additional filling of reservoirs. In case when
reservoirs have been filled in advance no quality deterioration is observed during
changeover
Preparatory operations Repair operations
prior to repair (e.g.,
ordering spare parts)

| 38
 Model Monitoring

Following possibilities under viewing View trends

trends are provided: Descriptive metrics Key metrics Deviations

Actual / model deviation Temperature 1 of
Oil temperature, deg. C Bearing 1 temperature, deg. C bearing, %

- Deviations
actual model

Actual / model deviation Temperature 2 of

- Actual and model parameters

Rotation frequency, rpm Bearing 2 temperature, deg. C bearing, %

- Signalizations by defects
actual model

Defects
Oil flow rate, kg/h
“Defect 2 of bearing” signalization

| 39 39
 API connection for external ERP,
CAD/CAM/PDM, MES and BI systems
Features

▪ Synchronize reference data

▪ Send documents (order, shift task, routing sheet)
▪ Obtain actual data (order/operation/machine operation/equipment/employee)
▪ Transfer any CNC machine operation data

| 40
MES/ERP Integration (SAP as an example)

SAP HCM SAP MDM SAP ERP

Sales orders,
Organizational Materials productional orders,
structure, staff nomenclature working centers,
operations, norms

SAP MII/PI

Execution facts,
etc.

| 41
Integration process:
IDoc in the IDoc Interface SAP SIDE: MDC SIDE:
The most common integration tools For sending data to SAP MDCPlus is using SAP
Administration ( “envelope”)
used with SAP include: IDOC – PI. MDCPlus is sending the files in known for
Intermediate Documents. IDOC sends SAP system notation. And after that SAP can
Administration Data: Segments messages between systems, querying use information which MDCPlus sent. It also
for information. There are over 600 can be simple xml-document like in example:
Inbound/ IDOCs, and they are generally well
E1<name> Child outbound supported across versions. Also, it’s <?xml version=”1.0″ encoding=”UTF-8″?>
segment proccessing
possible to use another way to <n0:namespace>

EXTERNAL SYSTEM
SAP <Header>
E1<name> connection to SAP: ABAP Interfaces, <A>Value<A>
Child
segment RFC, BAPI if it’s needed. Mechanism of <B>Value</B>
<C>Value</C>
Customer connection to SAP system has to be <D>2018-08-07T10:57:04Z</D>
described in separated technical task. </Header>
E1<name> <A1>
<A2>
There are two ways to sending IDOCs: <A12>Value</A12>
<B>
E1<name> using MDCplus web-service or just <B1>Value</B1>
saving IDOCs to shared folder. After all <B2>Value</B2>
E1<name>
MDCPlus will collect this file, parse it <B3>Value</B3>
</B>
and will use data. All these features
have to be described in separated <B>
<B1>Value</B1>
Status technical task. <B2>Value</B2>
Status information proccessing <B3>Value</B3>
“Come is to OK”, “set it OK”, “IDoc in the </B>

target system (ALE service) </A2>

</A1>

</namespace>

List of all subsystem which are using in SAP, interfaces,

| 42 namespases, objects and methods have to be described and fixed
in technical task for integration.
 System Capabilities MONITORING GROUPS OF STATES

Machine time
ENTERPRISE 1
Loading 58% Production downtime
ENTERPRISE 2
Unregulated downtime
Loading 59%
ENTERPRISE 3 M&R
Loading 44%
ENTERPRISE 4 Technical downtime
Loading 45%
Unused time

▪ Analysis of key performance indicators of the Holding (standardized

benchmarks)
▪ Equipment divided in groups for analysis and benchmarking of KPIs
▪ Analysis of modernization program effectiveness, including audit of
the need to purchase new equipment
▪ Executive decision-making based on information flows in bottleneck
areas, equipment downtime, drilldown MRO performance control,
including procurement of spare parts
▪ Mitigation of risks for production of orders

| 43
 Intelligent Enterprise DASHBOARDS and
workplace analytics (v1)
Enterprise
MDCplus Enterprise ⍺ Enterprise ⍵ Enterprise ⍴
𝑎2 + 𝑏2 = 𝑐 2
Holding
Enterprise
Enterprise ⍷ Enterprise ⍬ Enterprise ␀
⍥

▪ Downtime groups OEE for the period

▪ KEY KPIs
Enterprise
▪ Dualization from Enterprise ⍺
enterprise to Enterprise ⍵
workshop, group of Enterprise ⍴
machines and Enterprise
𝑎2 + 𝑏 2 = 𝑐 2
operators

| 44
Intelligent Enterprise DASHBOARDS and
workplace analytics (v2)
Groups of machines and their states Group of enterprises/ manufacturing units and their utilization

Groups of machines and their OEE Group of enterprises/ manufacturing units and their states

OEE dynamics OEE dynamics

| 45
Architecture
ARM Holding level

Client part Server part

Web Server Web Server

ARM Holding
Start service Start service
DB Server
▪ Server MDC Holding – Kestrel, cross
Service of interaction platform web server, based on Windows
ARM Holding and Linux
with Zyfra MDCplus
Web Server
Client
▪ Database - PostgreSQL 9.6 and higher or
MS SQL Server 2014
Zyfra MDCplus Client ▪ Enterprise Data aggregation from MDC
Replication service
class of systems (cross platform apps on
Linux and Windows)
▪ Client Module – Web User Interface
(Available on any browser)

Enterprise 1 Enterprise 2 Enterprise 3 Enterprise N

Enterprise level

| 46
 ALL–IN Digital Manufacturing Enterprise
System
Zyfra MES | Zyfra PLM MDCplus | Zyfra MES | MDCplus | Zyfra MES |
Zyfra PDM | Zyfra PLM Zyfra PDM | Zyfra PLM
Zyfra MES | Zyfra PLM

Zyfra PDM | Zyfra PLM MDCplus | Zyfra MES |

Zyfra PDM | Zyfra PLM

MDCplus / Zyfra MES | Zyfra

Zyfra MES | Zyfra PLM
PLM

Zyfra MES | Zyfra PLM

MDCplus | Zyfra PLM

Zyfra PLM Zyfra MES | Zyfra PLM

MDCplus | Zyfra MES |

| 47 MDCplus | Zyfra MES | Zyfra PDM | Zyfra Zyfra PDM Zyfra PDM | Zyfra PLM
PLM
MORE THAN
270 COMPANIES
ALREADY USE
ZYFRA SOLUTIONS

USE CASES

| 48
 Indian Railways
Building centralized monitoring system
Machine data collection system MDCplus

Task
✓ Measured parameters monitoring Improved machines
Equipment workload monitoring
efficiency
✓
✓ Downtime management
✓ Automation of maintenance and dispatching service
✓ Connection to any kind of CNC under the centralized software

MDCplus named as
standard monitoring
Result ✓ Improved machines efficiency tool for all workshops
✓ Software has been named as a standard solution
for all railway workshops
✓ Connected CNC machines, legacy machines, robots,
welding machines

| 49
 Implementation of Digital Manufacturing
execution system
Machine data collection system MDCplus

25%
✓ Increase output at current costs
Task ✓ Equipment workload monitoring
✓ Reducing the stopping production risks
✓ Automation of maintenance and dispatching service Increased labor efficiency
✓ Effective project planning taking into account the real worlload
of equipment and the real labor intensity of technological

1000+
processes

✓ 1000 + CNC machines in project Machines in project

Result ✓ Labor efficiency increased on 20%
Delays decreased on 30%
10%
✓
✓ KPI’s and benchmarks execution increased on 10%

Equipment utilization increase

| 50
 Spare parts manufacturing
efficiency enhancement
Machine data collection system MDCplus

Task Increase equipment productivity to meet the

deadlines when executing orders

Solution
✓ Machine tool holding has been connected to a common
informational space.
31%
✓ Input-output terminals have been installed to determine the causes equipment loading pull-up
of equipment downtime.
✓ Control of energy consumption by the machine drives has been

1.2
implemented.
million euros
Result ✓ 49 machines connected annual operating revenue increase
✓ 3,300 machine hours per month — discovered production time
reserves
✓ 3,965 euros — monthly net income from sale of additionally
manufactured products
✓ 31% — increase in machine load
✓ 1.2 million euros — enterprise annual operating revenue
increase
| 51
 Increasing effectiveness
in non-tire rubber goods production
Machine data collection system MDCplus

✓ Decrease the amount of defects attributed to

Task
10%
process failures / disruptions
✓ Increase the level of production monitoring
and analytical reporting
✓ Increase the accountability of maintenance reduction in energy losses
departments and reduce maintenance time

10%
Result ✓ Reduction of energy losses attributed to inefficient optimization of equipment
equipment switching on / off by 10% overhaul costs
✓ Optimization of equipment overhaul costs by 10%.
✓ Acquisition of reliable information to fill in the
working time registered by 95%

| 52
Zyfra MDCplus Benefits

Connection to any machine Computerized maintenance management system

Wide CNC controls support Tablets and smartphones app
Automatic / manual data collection Energy and video monitoring
Report generator Vibration Analysis
EMAIL & SMS messaging Open API and database architecture
CNC program management Secure data transfer
Job scheduling ERP and MES integrations

| 53
Support Center

Software 24/7 System

Updates Support Customization

Version update Round-the-clock online support Customizable Reports and Charts

from Helsinki & Russia (opening
At least 4 new releases soon) Development of specific
per year functions to fulfill customer
In-person training hosted requirements
by resellers

Downloadable product
documentation and tutorials

Technical support: support@mdc-

plus.com
+358 (0) 40 547 9229
| 54
Leninsky prospect 15А,
Moscow, 119071

+7 (495) 665-91-31
info@zyfra.com

Pasilankatu 2,
Helsinki, 00240

+358 (0) 9 3158-95-80

hello@zyfra.com

zyfra.com
mdc-plus.com
zyfra.ai

Thank you for your attention