Process and Machine Data Analysis

This project will show you how you can automate the evaluation of any production process and machine.

You can download the compiled files here or get the whole repository from GitHub.

With this system you will be able to automatically evaluate key figures like throughput, up-time, idle-time or energy consumption of every production machine or utility equipment like compressors, boilers, chiller.
Furthermore, you can automatically evaluate key figures like process time or product quality of every production process.

Since I started the project I’ve spend a lot of time to learn coding and at this point I’m aware of the bad coding style of the project.
I uploaded it anyway, because it works and I’m sure that it can be very useful.
It will be a huge help if you apply it in your production, but you should definitely be careful to NOT take this as an example of how to write code!


1) Overview over the Process and Machine Data Analysis Project

In this video I will give you a quick overview over the whole project and will briefly explain the setup of the system.

System Setup

2) Copy Files Program

In this video I will explain the function of the CopyJob.exe program.
This program is responsible for copying the log files of the machine or process you want to evaluate from the production network to a place where the database on a server in another network can reach them.

In the download from my website or the compiled code from GitHub you will find a folder called CopyJob.
In it there are two important files.
First: generalCopyJob.exe
This file is the actual program that copys the log files.
The execution of this program can be automated with a scheduled task.
Second: Configuration.xml
This file contains the configuration parameters for the copy program.

In the folder called Cryptography you will find a simple windows forms program.
This program will help you to encrypt the passwords for the user logins you need to store in the configuration file.

3) Database Update Program

In this video I will explain the function of the DB_Update.exe program.
This program is responsible for updating the MySQL database with the data from all the log files we copied in the previous step.

In the download from my website or the compiled code from GitHub you will find a folder called DBUpdate.
In it there are two important files.
First: DB_Update.exe
This is the program which updates the database.
The execution can also be automated as a scheduled task, which should run a few minutes after the CopyJob.exe.
Second: Configuration.xml
This file contains the configuration parameters for the update program.

4) Data Visualization with Windows Forms

In this video I will show you an example of the process and machine data visualization using windows forms.

This automated visualization can be used to get a quick overview over the most important production key figures.

This is the point where you can get creative and design your own reports that best represent the key figures of your production that you are interested in.
The visualization of the data in windows forms like in this video is just one example to give you an idea of whats possible.
For your specific case you can choose another presentation format that best suits your needs like automated E-Mails, a Website, PDFs or the evaluation in Excel.

5) Data Evaluation with Excel

In this video I will show you an example of how you can do a more detailed analysis of the data using excel.

This visualization will allow you to take a more detailed look into your data to identify problems and optimization potentials in your production.

Again, this is a point where you will have to adapt the templates to your own production and the key figures you are interested in.
After you have automated the data acquisition from your machines and processes to your database, you can then use that data to analyze your production.
You can load the data from the MySQL database to excel and feed it to some pivot tables or other calculations.
This will allow you to quickly filter the data for the parts you are most interested in.