Process quality and traceability
Process parameters from the PLC, lots from the line database, orders and scrap from the ERP, all in the same engine. Every lot has its process history, and an alarm goes off when a parameter leaves its window while the lot is being made.
Illustrative scenario: it describes a typical case, not a customer project.
When a lot is scrapped, the question is always the same: what changed?
Process parameters live in the PLC, the list of lots in the line database, scrap and non-conformities in the ERP. Rebuilding a lot's history means exporting from three systems and pasting into a spreadsheet, days later.
In Muvia the three sources land in the same engine and join on the lot. Every number in a report traces back to the tag and the source it came from, and you can ask “what was different about the scrapped lots” in plain words.
- Who it's for
- Quality managers, process engineers, shift supervisors and whoever answers customer complaints.
What you get
- Each lot's history in one place
- Parameters, order and inspection result sit together, with no exports from three different systems.
- Every number has an origin
- From the report you trace back to the tag and the source, which helps when a customer asks about a lot.
- Deviations caught during production
- A parameter outside its window is flagged while the lot is on the line, not at final inspection.
- Quality questions without waiting for a report
- Whoever looks after quality asks Athena and sees the SQL behind every answer.
For the technical team
How it is built in Muvia
- 1
Connect process and lots
On the edge node you configure the OPC UA and S7 drivers for the parameters and the SQL Server driver that reads the line's lot table. From the ERP you copy orders, lots and scrap, on a schedule and incrementally.
- 2
Model the lot
In the data model the lot ties together parameters, order and inspection result. Lineage shows which tag and which source every field in a report comes from.
- 3
Watch the window during the lot
For each parameter you set the allowed window; a threshold with a deadband opens an episode when the value leaves it while a lot is running, and the shift supervisor picks it up from the alarm register.
- 4
Ask Athena
“Which parameters were different on this month's scrapped lots?” Athena writes the query, compares good and scrapped lots and shows the SQL it ran, so the answer can be checked.
- 5
Score lots, if you want to
A Python function with a scikit-learn model trained by your team gives each lot a score and writes it next to its parameters. You tune the model yourselves, on your own data.
SQL query
SELECT q.result,
count() AS lots,
avg(p.furnace_temp_avg) AS furnace_temp,
avg(p.pressure_max) AS pressure,
avg(p.cycle_time_s) AS cycle_time_s
FROM lot_parameters AS p
JOIN erp_quality AS q ON q.lot = p.lot
WHERE p.started_at >= today() - 30
GROUP BY q.result- The data it needs
- Furnace temperatures and times from an OPC UA server
- Pressures and cycle times from a Siemens S7 PLC
- The lot table from the line's SQL Server database, read by the node
- Orders, lots and scrap records from the ERP, copied from SQL Server
More cases in this line
All use cases- Anomalies and predictive maintenanceVibration, temperature and current read from the PLC become a deviation from normal, a health index and, if you want, a score from a model of your own, in the cloud or on the node next to the machine. When a signal drifts, an alarm goes off and maintenance hears about it.
- Connected machines for machine buildersEvery machine you sell carries a Muvia node, and every customer gets a company of its own, kept apart from the others. Your service team follows the whole fleet with one login, and each customer gets dashboards and reports on their machine.
- Energy use per line and per pieceMeters and power analysers read over Modbus TCP, joined with the pieces produced and the orders in the ERP: how much energy each line, each shift and each piece takes, with an alarm when consumption looks out of the ordinary.
Tell us which machines you run. We'll tell you how to read them.
PLC brand, protocol, how the floor is connected: with those three answers, in a demo with one of our engineers, we show you how Muvia Industrial puts line data next to the rest of the business.