BITMOTECO Machine Monitoring
The innovative solution for machine data acquisition (MDA) and production data acquisition (PDA)
You would like to use your machines and systems …
Increase productivity?
Increase availability?
Record the conditions?
Record the order-related use of resources?
Automate repetitive manual tasks?
Increasing energy efficiency?
Get to know BITMOTECO machine monitoring!
BITMOTECO Machine Monitoring - Dashboard
We increase machine availability by 5-30% and reduce the effort involved in data acquisition.
BITMOTECO Machine Monitoring
Success Stories
At Bitmotec, customer benefit and customer satisfaction are our top priorities. We provide you with comprehensive advice. We support you from the planning to the individual application operation of your machine data acquisition (MDA) / production data acquisition (PDA).
“Quickly and easily record the availability and order-related OEE key figures in our production? With Bitmotec’s high level of expertise, this is no problem”.
Thomas Schubert
CEO – T&O Display Solutions GmbH
“At ibk, we stand for complete, turnkey solutions. BITMOTECO machine monitoring is exactly that and helps manufacturing SMEs to easily digitize their own machinery and increase machine availability.”
Christian Torp
Technical Director – ibk IngenieurConsult GmbH
“Bitmotec’s technology impressed me with its rapid integration and measurable ROI. Thanks to the high level of expertise in the areas of networking, analysis and presentation of machine data, projects can be implemented efficiently.”
Volkmar Hauser
Management consultant and former Executive Vice President and member of the Executive Management Board of Jenoptik AG
Functions
of BITMOTECO machine monitoring
01.
Data acquisition
02.
Data storage
03.
Data analysis
04.
Provide results
Interfaces
All machine types can be connected
Retrofit possible
Data provision for existing systems
- MES, ERP and co.
Easily expandable via GUI or SDK
- Integrated MDE terminal
Dashboards
- Machinery
- Single machines
- Machine comparison
- Planning views
- On the machines for the machine operators
- Trend analysis
- OEE: quality, performance, availability
Reporting
- Automated
- Trends
- Standard reports
Customized reports easily expandable according to your requirements
Security
- On-Premises
Your data stays in your company
- Remote access possible
- User administration
- Role-based access rights
Virtualization: Isolation in virtual machine
- Updates
Modular
- Scalable
Compatible with other BITMOTECO solutions
- Further use cases can be realized (condition monitoring, predictive maintenance, etc.)
Expansion of the range of functions possible through special requirements
Individually customizable through configurations
Technology
IoT platform BITMOTECOsystem as a strong technology basis
Future-proof: AI can be integrated and connected
MQTT message broker for Industry 4.0 networking
The operation of the solution is suitable for the IT requirements of both SMEs and large companies
Flexible machine data acquisition
We know that different requirements in the industry call for different solutions. Three highly functional options are therefore available to you.
The best thing about it?
You can use all three options at the same time!
Manual input, retrofitting and the machine interfaces complement each other perfectly in an inhomogeneous machine park.
Depending on your current and future requirements, you can put together your customized data capture solution from the available options.
Machine interfaces
A large number of machine interfaces are directly supported: OPC-UA, MQTT, MTConnect and Modbus TCP, among others. Additional special interfaces and protocols can be easily integrated on a modular basis.
For highly automated and continuous condition monitoring with the highest data precision.
Retrofit – Sensor integration
For existing machines without data interfaces. With our industrial-grade sensor retrofit kit, you can upgrade your machines quickly and easily.
Integration is non-invasive and does not require any intervention in the control system or safety-related changes.
Manual input
Machine statuses can be transmitted manually at any time via special input dashboards(MDE terminals).
This is useful for scenarios where continuous and automated data collection is not necessary or economical.
Expert support included for 3 months – integration, commissioning, analyses
“Successful production optimization is a continuous process. In addition to the technology, we support you with recommendations for action. With your new automated machine data analyses and our expert knowledge, the full potential will be unleashed.”
▪ Expert support
An expert will assist you with your production optimization free of charge in the first three months after commissioning
▪ Monthly recommendations for action
Discuss your results on a monthly basis and receive recommendations for action from our experts
▪ Integration
We support you free of charge with the integration of the software into your IT infrastructure
▪ Individual customizations
Including 8 hours of support for commissioning, training or individual adjustments to the system
Your added value
- ROI in 6 months
- Suitable for every machine
On-Premises:
Data sovereignty in your company without a cloud service- Dynamically scalable:
From the individual machine to the entire machine park - Easily expandable and customizable:
- Interfaces and connections
- Dashboards
- Input options
- Sensors
- Etc.
Comprehensive expert support
- Ready to use in no time
Demo appointment for BITMOTECO machine monitoring
Get to know the BITMOTECO Machine Monitoring system in our live demo and get an insight into its application in practice.
You will also receive a free ROI calculation for BITMOTECO Machine Monitoring from us to see what impact our solutions can have on your company’s bottom line.
Get in touch with us and arrange a free demo appointment for BITMOTECO Machine Monitoring. We look forward to helping you achieve your business goals!
André Heinke
Head of Sales & Marketing
FAQ - Frequently asked questions
Frequently asked questions about BITMOTECO Machine Monitoring
Management
With our machine monitoring solution, you can expect a 5-30% increase in machine availability, resulting in optimized production times and thus increased efficiency. Plus, our automated solution saves you 40-90% of time on data collection and analysis, so you can make faster, more informed decisions. Our solution also has an indirect impact on energy consumption, as it leads to more efficient operating times and thus uncovers potential for optimising energy consumption in your production process.
The technical solution enables continuous automated monitoring of the machines by continuously recording and analyzing relevant data. As a result, potential problems and optimization potentials can be identified at an early stage and unplanned downtimes and downtimes can be minimized. In addition to the technical solution, our company actively contributes to process improvement by offering regular review appointments with experts. In these meetings, we jointly analyze the collected data and identify optimization potential. Through regular exchange and cooperation with our customers, we help to continuously improve the production process and constantly increase machine availability. Our goal is to help you maximize your efficiency and achieve your production goals over the long term.
Our solution generates comprehensive data on machine availability, running times and downtimes, as well as time-series-based machine states. As a manager, you can use this information to compare planned production times with actual running and downtimes. This gives you a better overview of the efficiency of your production planning and the actual utilization of the machines. The ability to analyze the data manually allows you to plan more accurately and use resources more efficiently in the long term. This allows you to identify bottlenecks and overloads in time and make appropriate adjustments to optimize your production process and ensure smooth and efficient production.
You can expect noticeable improvements in a short period of time. After commissioning, our system automatically provides you with up-to-date evaluations that you can use to optimize your processes, planning and calculations. Automated data collection and analysis saves 40-90% of your time, allowing you to make informed decisions quickly. We offer a strong combination of the technical solution we have developed and at the same time support from our expert knowledge of production processes. In this way, we guide you to an effective improvement of your production process. Through continuous data analysis, we quickly identify optimisation potential, which we look at in a targeted manner in joint regular review meetings. Our team of experts is always on hand to help you and works closely with you to achieve sustainable improvements.
The long-term cost savings must always be considered individually for each customer. That’s why we will provide you with a free ROI calculation for BITMOTECO Machine Monitoring, which is precisely tailored to the needs of your company. This is usually done in the first demo appointment so that you quickly have all the costs and savings potentials available. With these results, an informed decision can then be made.
Our solution is designed to bring you economic benefits quickly. The return of investment (ROI) for BITMOTECO Machine Monitoring is on average 6 months. With our free ROI calculation tool, we can quickly and easily determine your individual ROI based on the most important key figures.
Our solution for machine monitoring and optimization can be used in the following industries :
1. Automotive: For monitoring and optimizing the production lines and manufacturing processes of automotive manufacturers and suppliers.
2. Electronics Industry: To improve production processes in the manufacture of electronic components and devices.
3. Food industry: For the optimization of production facilities in food processing and packaging.
4. Metalworking industry: To use machinery and equipment in metalworking more efficiently and minimize downtime.
5. Plastics and chemical industry: To monitor machinery in the production of plastic products and chemical products.
6. Woodworking industry: For optimizing the production of wood products and monitoring woodworking machinery.
7. Pharmaceutical Industry: For the monitoring of machinery and equipment in pharmaceutical production.
8. Textile industry: To increase the efficiency and availability of textile machinery in the production of textiles and clothing.
Yes, our solution is designed to meet the specific needs of your production and processes. Our team of experts has extensive knowledge in industrial software, production technology and mechanical and plant engineering. This allows us to tailor the desired solution to your individual needs and integrate it into almost any production environment.
The focus of our solution is on increasing machine availability and optimizing Overall Equipment Effectiveness (OEE). OEE is a standardized performance indicator that can be applied across the manufacturing industry. Therefore, our solution can be used in various industries, as the fundamentals for efficient production and improving machine availability apply universally.
Our solution is designed to integrate seamlessly into your existing infrastructure. The technical requirements for implementing our solution are usually straightforward and are met by most companies. You need an infrastructure that allows the sensors to be installed on the machines and data to be transmitted to your server. Our team of experts is here to help you integrate into your operations and ensure that all technical aspects run smoothly. For specific technical questions, we are happy to refer you to our IT FAQ or the FAQ for Operations Engineers, in which we provide detailed information.
Our technical solution is usually compatible with your existing infrastructure, but some specific customizations are required. To use the solution, a server is required for the software as a virtual machine (VM). The retrofit sensors require power and a network connection to collect and transmit the required data.
Connections to your existing MES (Manufacturing Execution System) or ERP (Enterprise Resource Planning) systems are possible on a customer-specific basis and are implemented via standard interfaces. Our experts will work closely with your team to ensure the integration runs smoothly and ensures that the solution is seamlessly integrated into your infrastructure.
Our solution is highly flexible and adaptable, allowing it to adapt to the changing needs of your production processes and infrastructure. We understand that businesses evolve over time, creating new requirements. That’s why we’ve designed our solution to be scalable and extensible.
Yes, we offer comprehensive training and support to ensure that you and your employees can always use the solution effectively.
1. Integration: Our team of experts will help you seamlessly integrate the solution into your operations, ensuring that the implementation runs smoothly.
2. Initial Introduction and Training: At the beginning, your employees will receive comprehensive training that lasts about 8 hours. All relevant aspects of the solution are explained so that your employees are familiar with the functions and operation.
3. Accompaniment and continuous process improvement: Our support team is available to you even after the initial implementation and continuously accompanies you in process improvement. We support you in optimizing your production processes and help you to exploit the full potential of the solution. Our goal is to ensure the effective use of the solution. Thus, you can benefit from the advantages of our solution in the long term.
We offer long-term support and maintenance agreements that are individually tailored to the needs of our customers. Depending on your requirements and preferences, you can choose the right support and maintenance option. Our support team is at your disposal to quickly resolve any technical issues you may have. We also offer remote support if you allow it. In many cases, remote maintenance allows us to solve problems quickly and efficiently without the need for an on-site visit.
Your data sovereignty is very important to us. Our industrial software enables data sovereignty without a cloud service. This means that all your production data is stored securely and locally on your own servers. This gives you full control over your sensitive company data and you can be sure that it is not stored in external cloud services.
Production
With the help of the solution, it is easy to see whether the operation of the machines is running according to the planned production time. The precise determination and presentation of unplanned downtimes enables the subsequent simple analysis and determination of possible causes. As a result, errors can be corrected and the production process can be significantly improved.
The solution provides key figures on machine availability, runtime and downtime of each machine. In addition, there is a time-series-based, clear display of the machine statuses.
With the help of the solution, it is recorded when and how long a maintenance lasts. By analysing further downtimes that occur, it is possible to identify future time windows of potential downtimes. As a result, scheduling maintenance is more efficient, which ultimately leads to a reduction in downtime.
Vibration and current data, which can be recorded by means of acceleration and current sensors, are particularly suitable for measuring the machine condition in order to be able to determine machine availability. The machine condition can also be determined with the help of data that is collected directly from the control system. Depending on the application, data from other sensors can also be useful, which is why the solution supports the entire repertoire of IO-Link sensors.
The solution displays the current machine status with a delay of a few minutes. The information on machine availability is provided every 24 hours for the previous day.
Project-specific alerts are configurable.
The sensors are connected to the BITMOTECOsystem via IO-Link Master. These masters require a 24 V power supply and an Ethernet network connection.
For the integration of the solution, it is necessary to attach an IO-Link sensor to each machine to be monitored. In addition, each sensor must be connected to an IO-Link master with an IO-Link cable. Up to four sensors can be connected to one master if this makes logistical sense. The masters require a 24 V power supply as well as a network connection via Ethernet. In addition, it is necessary to deploy the BITMOTECOsystem as a virtual machine in the network so that it can communicate with the masters.
The solution does not directly intervene in the production process or the daily operation of the machines. However, thanks to the insights gained from the data collected by the solution, there is a constant improvement in production processes.
The data processing and analysis takes place locally and containerized in the BITMOTECOsystem. Access and display of the data is therefore only possible by means of user authentication.
Security and functional updates for the BITMOTECOsystem are made available for download by the provider (Bitmotec GmbH). These can then be uploaded to the BITMOTECOsystem independently by the customer.
Following the final integration, employees will receive an introduction to the effective use of the solution at the company’s request.
If an error occurs, it is possible to inform the provider (Bitmotec GmbH) via a ticket system, which allows them to fix it promptly and provide an update. For further technical assistance, it is a good idea to book an appointment with support for live remote assistance.
The provider (Bitmotec GmbH) provides support in all phases, from integration planning to the final commissioning of the solution.
IT administrator
The BITMOTECOsystem can be operated as a virtual x86-64 machine on all common hypervisors (Hyper-V, VMware, VirtualBox, etc.). The prerequisites for this are min. 4 cores, 4 GB of RAM and 32 GB of hard disk space.
Basically, all TCP/IP and UDP/IP based application protocols are supported. Depending on the desired application protocol, data can be received directly via Node-RED (e.g. MQTT, Modbus TCP, OPC-UA, BACnet and HTTP(s)) or via a corresponding (customer) gateway container (e.g. IEC60870-5 to MQTT). For other protocols that do not belong to the Internet Protocol family, an external, upstream gateway is required for protocol conversion.
The sensor hardware and all (virtual) IP networks over which an unsigned or unencrypted transmission of data takes place must be protected against access by unauthorized persons by appropriate means.
Which networks and ports should be configured in the firewall for the solution to function properly?
For the GUI, ports 80/TCP and 443/TCP of the BITMOTECOsystem must be accessible. In addition, all networks and ports required for communication with external sensors or other IT systems must be activated.
Commissioning instructions are provided with all the information required for the installation and integration of the BITMOTECOsystem. In addition, a free appointment can be booked with support for live remote assistance.
Due to the incoming transmission of sensor values to the BITMOTECOsystem and the outgoing transmissions of stored measurement series to any dashboards, the demand on network capacity increases. Otherwise, there will be no further impact on existing IT systems and solutions.
The data load caused in a time interval can be roughly estimated as follows: Number of sensors * Size of measured values transmitted in the interval + The sum of the values displayed in the respective dashboard panel * The number of viewers.
Conflicts with other IT systems can only arise due to the accidental collision of the preconfigured IP subnets. The subnets used can be found in the documentation. In order to avoid collisions during commissioning, all IP subnets used can be reconfigured in the BITMOTECOsystem.
The IT department should commission the sensors and the BITMOTECOsystem as an edge device or as a virtual machine and integrate it into the corresponding in-house IT and OT networks. For this purpose, it is necessary to ensure successful network communication between the BITMOTECOsystem and any sensors, machines and gateways.
Access to the user interface, the measured and analytical values as well as the integrated MQTT broker is only possible with prior user authentication. The software components run containerized and thus isolated from each other on the BITMOTECOsystem except for the required network communication.
Ways to fully back up the system are available. The integration into a backup concept and the execution of the backups are the responsibility of the user.
The IT department can set up SSH access to the BITMOTECOsystem, monitor and administer it via the console.
The BITMOTECOsystem does not have an integrated VPN solution. However, external management via HTTPS or SSH can be implemented via a VPN solution already available in the company network, after consultation with the customer.
The sensors used are non-invasively attached to the outside of production machines and are only used for condition monitoring. The software provided runs in the form of modules containerized on the BITMOTECOsystem. As a result of this isolation, individual components can only communicate with other modules or network participants via the Internet Protocol. To ensure the safest possible operation, Bitmotec GmbH provides regular updates for all system components.
Bitmotec GmbH offers active support from implementation planning to integration and regular maintenance of the BITMOECOsystem. For example, a free appointment with support can be booked for live remote assistance with integration. For end users, training courses can be booked for general use and for the individual modules.
Security and functional updates for the BITMOTECOsystem are made available for download by the provider (Bitmotec GmbH). These can then be uploaded to the BITMOTECOsystem independently by the customer.
BITMOTECO Machine Monitoring at a glance
Download the product flyer for BITMOTECO machine monitoring.
More on the subject of machine monitoring:
An introduction to machine data acquisition (MDA) / production data acquisition (PDA)