Industry 4.0 solution for production improvement

The Nexeed Production Performance Manager is the Industry 4.0 software solution for systematic production improvement. The software helps quality and maintenance management associates in decision-making and thus makes their everyday work easier. Individual modules aid in this process with functions that are specific to certain areas, such as predictive maintenance or real-time process monitoring.

This software harmonises various pieces of production data. It can extract customised information from this data and apply production knowledge automatically. The processed information is made available to the user directly for specific purposes. Consequently, response times can be shortened, faults can be prevented, tasks can be assigned and newly acquired information can be accessible.

In addition to the software solution, the corresponding service options have also been customised to the demands of the user – depending on demand, customers can receive a use case consultation. Starter kits offer support in the introduction to the new software. Bosch can take on the installation and operation if desired. After installation, Bosch experts assist customers through comprehensive support and train associates so that they can work with the new system quickly and without problems.

The Nexeed Production Performance Manager operates as a stand-alone solution. Due to its open interfaces, it can be combined with other solutions, such as an MES extension. Customers benefit from the ecosystem and the open Industry 4.0 standard Production Performance Management Protocol, offering fast and easy machine connectivity.

For the plant manager, it’s the big picture that counts: they need an up-to-date overview of the condition of all machines as well as up-to-date analyses at all times. Condition monitoring, meaning the permanent recording of machine states by measuring physical variables, forms the basis of the software. Production and machine data is collected and harmonised centrally and can be retrieved on any terminal. This makes it possible to both easily monitor and systematically optimise production.

The Nexeed Production Performance Manager displays measured values of machines and sensors as well as machine messages live and in chronological order. The current state of production can be determined quickly and short-term decision-making in the event of faults is simplified. For long-term increases in efficiency, the user has access to analysis options, for example sorting of fault messages by frequency. This makes it easy to see where failures or bottlenecks occur on a regular basis. This information is important when it comes to overall production and resource planning.

Process and quality engineers want a transparent, fault-free and continuous process that ensures products of impeccable quality. The Process Quality Module can be used to monitor and document process data in real time. This transparency helps users keep an eye on quality at all times and therefore improve the cost-effectiveness of production.

Via a cockpit, the Process Quality Module displays the parameters and tolerances in such a way that any problems that occur can be detected and remedied quickly. Due to the analysis function, systematic faults and tendencies are detected earlier and their causes are isolated. This allows process engineers to take measures before faults occur. This module is suited for obtaining transparency quickly regarding joining or coating processes.

For maintenance technicians, work used to start with a report of a machine failure – in the networked factory, predictive maintenance ensures that it doesn’t even come to this in the first place. With the Nexeed Production Performance Manager, they have a powerful and easy-to-use tool at their fingertips that they can use to detect and remedy possible machine downtimes at an early stage. For example, the system warns the maintenance technician early, if a motor is about to overheat or if parts of a system show signs of wear.

The software monitors defined parameters in the production process and immediately notifies users when warning limits are exceeded or process-threatening trends become apparent. Maintenance technicians can use the Data Processing Module to select the underlying rules from a catalogue and configure them individually. The generated notifications can be forwarded directly to the responsible person. In conjunction with the Ticket Management Module, this happens automatically according to an optimised servicing schedule that sorts tickets by urgency and assigns them according to both qualification and responsibility. The Nexeed Production Performance Manager is an Industry 4.0 tool that can be used within production. With open interfaces, a high level of connectivity and modular expandability, the software will continue to provide flexibility in the future.
The networking of software, sensors, machines and production lines is crucial for long-term increases in efficiency. In particular, the easy connection of new Industry 4.0 products makes production adaptable and agile. The Production Performance Management Protocol, Bosch’s open-source machine language and the open documented interfaces, allow users to implement their own and third-party solutions in the existing IT ecosystem.

Also, the associate is more involved, because even without IT knowledge, they can use the software independently to implement applications – this allows everyone’s knowledge and experience to be used to increase efficiency. The software is not a closed system, but is always evolving thanks to updates and module expansions – and therefore adapts to the current requirements.