MDC-Max is a real-time machine data collection system that gives you instant reports and charts about your shop floor productivity. In today’s complex and competitive global markets, it is more important than ever to maximize effective use of manufacturing equipment. MDC-Max provides powerful machine data collection and analysis capabilities to make this task easier and gives you real time reports including Overall Equipment Effectiveness (OEE). All of this can be achieved without the need to place PC’s beside the machine tools – all the data can be collected by cable, wireless or ethernet (network) and is stored centrally even if you have multiple workshops to monitor. MDC-Max integrates with the latest version of the most trusted CNC Communication software on the market DNC-Max. With over 100 available report templates you can easily display your data to enable you to explore down to the appropriate level to see exactly what is happening with your production schedules.
• Cycle Time per Part (min, max and average)
• Number of parts per shift / operator
• Number of scrapped parts
• Machine downtime
• Scheduled Maintenance
• Unscheduled maintenance
• Setup Time per part
• Operator effectiveness
• Overall Equipment Effectiveness (OEE)
• Realtime Machine Display (see which machines are running at a glance)
Basic Machine Data Collection
Some companies only want to know if a particular machine is running and producing or if it’s stopped. The basic data collection will produce charts to show the amount of time the machine has been in production and the amount of time allocated to downtime. It is then up to the supervisor to ask the operator why the machine was not running.
Advance Machine Data Collection
With Advanced Machine Data Collection we can provide accurate reporting of the machine tool efficiency on any job. We can show the total percentage of downtime for each type of machine stoppage such as Tooling, Setting and Machine Maintenance etc. This additional information is provided by the operator using a barcode reader. The operator simply scans a barcode to indicate the reason for the machine downtime. This information can then pin point exactly what is causing a loss of production.
• Operator ID login – MDC-Max knows who is logged onto the machine
• Setter login – MDC-Max can separate out setting time for each job
• Maintenance ID login – MDC-Max can separate out maintenance from downtime
• Waiting for material – operator swipes this to say he is waiting for stores
• No job – there are no jobs waiting for the machine
• Scrap part – the last part was scrapped so remove it from the good part count
• Tool broken – the operator is waiting for a setter
With the MDC-Max Web Client we have taken operator events to the next level. The web client can display your live screens and be customized to send any operator event you can think of. Machine status and operator events can be accessed directly in the web client interface making it extremely easy for operators to send downtime reasons for a specific machine.
The web client is optimized for even the smallest displays using responsive design techniques. This means you can access the same interface on smartphones, tablets, and
PCs. Thereby the traditional operator screen at the machine has become mobile and can fit in every operator’s pocket. This is not only convenient for the operator, but also a cost-efficient alternative to having client PCs or barcode readers installed at each machine.
The Tablet screen is divided into 3 sections
Status Area – this area displays the current status of the machine (up to 10 items) and typically shows the machine name, current job, machine status, cycle time and number of parts made. This data is for information only and can be configured at the time of installation. The data is updated in real time from the MDC-Max server.
Reason Code Area – this area can display up to 20 touch buttons for the operator to enter a reason code for whenever the machine is not in production.
Input Area – this area can have up to 3 input boxes which can be used to enter the current job number and operator name. The operator taps an input box and then types in the data using an on-screen touch keyboard.
How it Works
On a typical installation we fit one of our MDC units into the machine control. This unit is wired into the Cycle start and Parts counter relays. Every time the machining cycle or the parts counter signal is detected by the MDC unit a code is sent back to the MDC-Max software.
Because of the variety of types of machine controls the monitored signals may vary depending on customers requirements.
These codes are recorded in realtime on the computer system and can be displayed immediately in a graphical format.
If a machine is not in production for any reason the operator can scan a barcode to let the MDC-Max system know why the machine is stopped. These codes can be customised to suit your company but typical barcodes would be for the following reasons.
Waiting for Setter
Waiting for Maintenance
Waiting for Tooling
Waiting for Material
As MDC-Max records all this information you can then produce reports to see how much production time has been lost due to say waiting for tooling.
With over 100 available report templates you can easily display your data to enable you to explore down to the appropriate level to see exactly what is happening with your production schedules.
(see which machines are running at a glance)
Want to Increase your Profits
• Increase production
• Make more effective production decisions
• Highlight production bottlenecks
• Schedule machine maintenance more effectively
• Automatically Calculate your OEE
• Stop worrying about production deadlines
• See an immediate increase in production
• Tells you when machines are stopped and why
• Gives you the information to see what’s causing loss of production
The main benefits of having the MDC system from Cambridge Numerical Control is that I can see what production has taken place in real time. I can see when machines are in production and when they are not without the need to go out on to the shop floor. I don’t even have to be there as I can access the system remotely. MDC has given me a more accurate view of my personnel and production in general and I now have an effective tool to manage my nightshift. Since having the system installed we have seen an increase in production of 15% on the machines where the MDC system is installed. Cambridge Numerical Control are always there when I have a question and can fix most problems using the remote link they installed to our system. This means that they do not need to visit us and saves a lot of time.
WM Lee Ltd in Sheffield
Since having the system installed we have seen a big reduction in machine downtime. All the information regarding the current state of the machine is relayed instantaneously via the live screen and any stoppages are reported automatically. This has enabled us to keep track of production and minimise downtime.
At the end of each week we just print off the required reports and the information regarding job times, hours worked and down time per machine is all there. We have also had a very positive response from our work force, who no longer see it as Big Brother watching them. They know that if there is a problem with their machine, the management team see it immediately and can respond to it straight away.
The shop floor works more efficiently and we know the reasons for our downtime and the staff have suggested ways to minimise it. Since having the system installed we have seen an increase in production of 15% – 20% resulting in improved lead times and on-time delivery to our customers. Most of which has been achieved by utilizing the MDC System as a Production Aide and minimising our downtime.
The MDC system is a superb Management tool and I would highly recommend it.
Technoset Ltd in Rugby
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