How can visual process phenomena in production be systematically captured and analyzed?

Visual effects that cannot be measured using conventional sensors require a time-synchronous combination of image and process data. With ibaCapture, camera images and HMI visualizations can be recorded in precise synchronization with process signals. This makes purely visual phenomena analyzable and reproducible. In combination with ibaAnalyzer, these datasets can be evaluated in a structured manner, enabling clear identification of root causes.

How can production data be integrated into a LEAN management system?

Successful integration requires the standardized acquisition, visualization, and analysis of process data based on defined KPIs. With ibaPDA and ibaHD-Server, data is continuously collected and made available for analysis. ibaDaVIS enables transparent visualization in dashboards for shopfloor management and operational decision-making. In addition, ibaDatCoordinator provides automated reporting and supports the sustainable integration into LEAN processes.

How can strip breaks or surface defects be analyzed and prevented based on data?

The analysis of such faults requires high-resolution, continuous data acquisition combined with visual context information. ibaPDA ensures seamless recording of all relevant process parameters, while ibaCapture documents visual anomalies. By correlating both data sources, even complex material-related phenomena can be identified. Based on these insights, targeted process adjustments can be implemented to improve process stability.

How can production processes be efficiently monitored using automated reports and KPIs?

Automated reporting enables standardized and continuous evaluation of process conditions across shifts. With ibaDatCoordinator, reports and KPI analyses can be generated and distributed on a scheduled basis. ibaDaVIS complements this with real-time dashboards displaying condition values and event overviews. This provides decision-makers with a consistent basis for action without requiring manual analysis.

How can response times to process disturbances in production be reduced?

Rapid response requires real-time monitoring of critical process parameters and clear visualization of deviations. With ibaPDA, relevant data is continuously acquired and made available at high resolution. ibaDaVIS presents this information through live dashboards and event tickers. This enables immediate detection of tolerance violations and the prompt initiation of corrective actions.

Digital Process Optimization in Steel Refining at LSV

Success Story

The heat and surface treatment of steel is a complex and sensitive technical process where maximum reproducibility, reliable documentation, and complete traceability are essential. With the iba system, LSV implemented a comprehensive solution for digital data acquisition, analysis, and evaluation.

System Architecture Practical Application Used Functions More Success Stories

The heat and surface treatment of steel is a complex and sensitive technical process where maximum reproducibility, reliable documentation, and complete traceability are essential. At LSV Lech-Stahl Veredelung, steels are heat-treated, both conventionally and inductively, and the bar steel is further processed into high-quality bright steel.

As process complexity increased, the existing data acquisition system reached its limits. Common challenges such as outdated logger PCs, unstable data transmissions, raw data without context, and unstructured CSV files not only made data analysis more difficult but also hindered rapid problem identification, effective decision-making, and continuous process improvement. The goal was to establish a stable and centralized data architecture that enables reliable acquisition, evaluation, and visualization of process data, without requiring programming skills. The system should also help identify patterns, trace downtimes transparently, and support long-term, data-driven decision-making.

Solution with the iba System

With the iba system, LSV implemented a comprehensive solution for digital data acquisition, analysis, and evaluation:

ibaPDA handles continuous data acquisition directly from S7 controllers and other interfaces. The data is archived long-term via ibaHD-Server.
Visualization takes place live in the ibaPDA client and web-based with ibaDaVIS. Evaluations are carried out both ad hoc and historically using ibaAnalyzer.
For end users, regular reports are automatically generated via ibaDatCoordinator and an integrated mail server structure—either event-based or time-based.

Heated metal rod glowing orange in a machine.

Practical Application: Turning Process Knowledge into Action

With the new solution, LSV was able to effectively leverage process knowledge. In a pilot project, representative production orders with various product and material variants, along with their associated machine operations, were analyzed. The identified downtime periods led to targeted measures for improving plant efficiency.

Structured data foundation: Robust, centralized measurement data architecture replacing unorganized CSV files.
High transparency: Process data visualized in real time and available for historical analysis.
Informed decision-making: Analyses provide the necessary context and deliver actionable insights for improvement.
Increased efficiency: Downtimes are systematically recorded and effectively reduced.

The iba system provides us with robust and reliable data acquisition — exactly what we need for our demanding processes. It enables us to make data-driven decisions that sustainably improve our production.

Mohamed Bousnane
Project Engineer, LSV Lech-Stahl Veredelung GmbH

Used Functions

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

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Frequently Asked Questions (FAQ)

How can visual process phenomena in production be systematically captured and analyzed?: Visual effects that cannot be measured using conventional sensors require a time-synchronous combination of image and process data. With ibaCapture, camera images and HMI visualizations can be recorded in precise synchronization with process signals. This makes purely visual phenomena analyzable and reproducible. In combination with ibaAnalyzer, these datasets can be evaluated in a structured manner, enabling clear identification of root causes.
How can production data be integrated into a LEAN management system?: Successful integration requires the standardized acquisition, visualization, and analysis of process data based on defined KPIs. With ibaPDA and ibaHD-Server, data is continuously collected and made available for analysis. ibaDaVIS enables transparent visualization in dashboards for shopfloor management and operational decision-making. In addition, ibaDatCoordinator provides automated reporting and supports the sustainable integration into LEAN processes.
How can strip breaks or surface defects be analyzed and prevented based on data?: The analysis of such faults requires high-resolution, continuous data acquisition combined with visual context information. ibaPDA ensures seamless recording of all relevant process parameters, while ibaCapture documents visual anomalies. By correlating both data sources, even complex material-related phenomena can be identified. Based on these insights, targeted process adjustments can be implemented to improve process stability.
How can production processes be efficiently monitored using automated reports and KPIs?: Automated reporting enables standardized and continuous evaluation of process conditions across shifts. With ibaDatCoordinator, reports and KPI analyses can be generated and distributed on a scheduled basis. ibaDaVIS complements this with real-time dashboards displaying condition values and event overviews. This provides decision-makers with a consistent basis for action without requiring manual analysis.
How can response times to process disturbances in production be reduced?: Rapid response requires real-time monitoring of critical process parameters and clear visualization of deviations. With ibaPDA, relevant data is continuously acquired and made available at high resolution. ibaDaVIS presents this information through live dashboards and event tickers. This enables immediate detection of tolerance violations and the prompt initiation of corrective actions.