How can large volumes of historical production data be efficiently analyzed and visualized?

A high-performance long-term database with integrated trend visualization enables fast access to historical signal trends over extended periods. With ibaHD-Server, data can be continuously stored and flexibly analyzed using aggregated trend views. Users can seamlessly switch between long-term overviews and detailed analysis via zoom functionality, without requiring separate data preprocessing. This significantly reduces analysis time and facilitates the identification of trends and deviations.

How can a centralized data pool be provided for multiple departments in production?

A central data server enables simultaneous access to consistent process data for production, quality assurance, and maintenance. ibaPDA acquires data from various plants, while ibaHD-Server stores and provides it for long-term use. This creates a unified data foundation for analysis, complaint handling, and optimization projects. Cross-departmental data usage significantly improves decision-making quality.

How can continuous process data without defined start and end points be meaningfully analyzed?

Continuous data streams require specialized tools for flexible time range selection and aggregation. ibaHD-Server allows ad hoc analysis of arbitrary time periods and supports automatically aggregated views. This enables the investigation of long-term developments without prior segmentation. It is particularly relevant for processes without clear batch or product boundaries.

How can historical production data be leveraged for machine learning applications?

Machine learning models require a consistent, comprehensive, and high-quality data foundation. ibaHD-Server provides structured access to historical process data and enables data export for training purposes. In addition, data acquired with ibaPDA can be combined with other data sources. This supports the development of data-driven models for process optimization and fault prediction.

How can production data be integrated with external systems such as MES or reporting tools?

Efficient integration requires standardized interfaces and flexible access to historical data. ibaHD-Server enables access to data from various sources and their integration with external systems such as MES or reporting applications. In combination with ibaDatCoordinator, automated reports can be generated and distributed. This establishes a seamless data foundation for analysis, reporting, and operational control.

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In order to be able to answer questions about the process and production based on measurement data, Michael Vonwald, Head of Automation at Neuman Aluminium, introduced the iba system in 2014 in the slug and continuous casting production in Marktl. Due to its success, the area of application was subsequently extended to the entire site and thus rolled out in the extrusion plant as well as in the extrusion plant and at PREFA.

I am still a happy user of the iba system and I don’t think my ‘future life’ will be without iba!

Michael Vonwald
Head of Technology, Neuman Aluminum

Interview with Michael Vonwald

Head of Technology, Neuman Aluminum

How is the ibaHD-Server used at Neuman Aluminum?

In Marktl, we have many small systems and machines that we record together with an ibaPDA system. All data is then recorded on the ibaHD-Server. Here we have direct access to about one and a half years of data. In the visualization in the ibaPDA client, we can quickly get an overview of the last few weeks or an even longer period via the HD trend view. The advantage of the ibaHD-Server is that we can easily navigate and zoom into areas in the past in detail.

Which users do you have at your plant for the ibaHD-Server?

The three main departments, Production, Maintenance – which also includes Engineering and Automation – and Quality Assurance, use the data and findings from the ibaHD-Server. Our quality department uses this to have a quick overview of the data in the event of a complaint. We also use the ibaHD server as a data source for a reporting application: Here, the historical data is read and linked together with operating data from other sources in a report. Finally, our extrusion plant uses the historical data from the ibaHD server to supply a machine learning application with data and thus train it.
In my role as technical manager, I also continue to use the ibaHD-Server for analysis purposes.

What advantages do you see in the ibaHD-Server compared to the measurement files?

One of the advantages I see is that access for a “quick look” is very simple and uncomplicated. All I have to do is drag and drop the signals I want to view into the trend view. With a few clicks on the minus button, I can zoom out to half a year – but I can also quickly zoom back in again. The aggregations make it incredibly easy to get an overview of long periods of time without having to know in advance which period you want to look at. This gives you a very quick overview of the signal behavior, especially over long periods of time. And that absolutely speaks in favor of the ibaHD-Server compared to the measurement files – especially when we’re talking about continuous data recordings that don’t have a defined start and end point like product-based recordings. This means that if I want to look at trends over long periods of time, then the ibaHD-Server is absolutely top.

Do you also access the HD data offline from the ibaAnalyzer?

We now only use HD data for analysis with ibaAnalyzer. This means that all interactive analyses performed by users are carried out via HD queries. We now only use the measurement files for automatic processing with ibaDatCoordinator.

Are there any improvements or enhancements you would like to see?

Unfortunately, we do not yet use the function to save events in the ibaHD-Server. Of course, this would open up many possibilities for us: At this point, we are planning to record the start of all products as an event so that we can then quickly navigate to the start of the individual products based on these events. Unfortunately, we haven't done enough on this topic so far – it’s something that’s burning under my fingernails. So we will certainly tackle this in the near future.
I can't think of any improvements at the moment. I have to say that I am still a happy user. We are also growing with the iba system. For example, we have also established the ibaCapture video recording system and are enthusiastic users of it.

In addition to the option of saving events, ibaHD-Server now also offers the option of easily accessing historical data from external systems. Will you be using this function?

We have a self-developed MES system in use and it is very important that we can access the data properly. And ibaHD-Server would certainly be perfect for our requirements. As Head of Technology, this topic is also very important to me and I will definitely continue to pursue it, because I don't believe that my “future life” will be without iba.

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Used Functions

The following functions of the iba system are used in this success story.

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Frequently Asked Questions (FAQ)

How can large volumes of historical production data be efficiently analyzed and visualized?: A high-performance long-term database with integrated trend visualization enables fast access to historical signal trends over extended periods. With ibaHD-Server, data can be continuously stored and flexibly analyzed using aggregated trend views. Users can seamlessly switch between long-term overviews and detailed analysis via zoom functionality, without requiring separate data preprocessing. This significantly reduces analysis time and facilitates the identification of trends and deviations.
How can a centralized data pool be provided for multiple departments in production?: A central data server enables simultaneous access to consistent process data for production, quality assurance, and maintenance. ibaPDA acquires data from various plants, while ibaHD-Server stores and provides it for long-term use. This creates a unified data foundation for analysis, complaint handling, and optimization projects. Cross-departmental data usage significantly improves decision-making quality.
How can continuous process data without defined start and end points be meaningfully analyzed?: Continuous data streams require specialized tools for flexible time range selection and aggregation. ibaHD-Server allows ad hoc analysis of arbitrary time periods and supports automatically aggregated views. This enables the investigation of long-term developments without prior segmentation. It is particularly relevant for processes without clear batch or product boundaries.
How can historical production data be leveraged for machine learning applications?: Machine learning models require a consistent, comprehensive, and high-quality data foundation. ibaHD-Server provides structured access to historical process data and enables data export for training purposes. In addition, data acquired with ibaPDA can be combined with other data sources. This supports the development of data-driven models for process optimization and fault prediction.
How can production data be integrated with external systems such as MES or reporting tools?: Efficient integration requires standardized interfaces and flexible access to historical data. ibaHD-Server enables access to data from various sources and their integration with external systems such as MES or reporting applications. In combination with ibaDatCoordinator, automated reports can be generated and distributed. This establishes a seamless data foundation for analysis, reporting, and operational control.