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.

The iba System as Part of the LEAN Framework at thyssenkrupp Electrical Steel

Digital Process Optimization in Cold Rolling

At the cold rolling mill of thyssenkrupp Electrical Steel (tkES) in Gelsenkirchen, the team faced a familiar yet complex challenge: despite the availability of extensive measurement data, certain process phenomena remained unclear—particularly when it came to the visual aspects of production.

Solution Approach Benefits Used Functions More Success Stories

Critical observations made by operators could neither be documented nor analyzed collaboratively. At the same time, process disturbances such as strip breaks or surface defects were difficult to reproduce. To meet the company’s high standards for quality, safety, and continuous improvement, a system was needed that could create transparency, make root causes visible, and become an integral part of a sustainable LEAN process.

Solution Approach with the iba System

As part of tkES’s LEAN initiatives, the iba system was gradually integrated into key areas of the plant—from live monitoring to automated documentation:

ibaPDA and ibaHD-Server continuously record process parameters in high resolution, providing the foundation for ad-hoc analyses and long-term trend evaluation.
ibaCapture enables the synchronized recording of camera and HMI images with process data, allowing disturbances to be visually analyzed from the operator’s perspective for the first time.
ibaDaVIS presents this information in user-friendly dashboards, including HD live views, condition indicators, and event overviews.
ibaAnalyzer and ibaDatCoordinator generate standardized reports and KPIs for continuous evaluation and automated alerts, distributed via email.

Practical Example: From “Flowering” and Strip Breaks to Process Stability

The added value of the system became especially evident at the CVC reversing stand, where recurring strip breaks occurred at the beginning or end of the strip. With the implementation of ibaCapture, the phenomenon of so-called “flowering” was identified and documented — a local hardening of the material, visible only through optical inspection and undetectable by conventional sensors. The camera-based system made this issue visible and, together with the time-synchronized process data, enabled a structured root-cause analysis.

Since then, the camera has become an active tool for operators in fault diagnosis. In the combined annealing, shot blasting, and pickling line, the strengths of the system are equally evident. An automatically generated daily HD report provides all process engineers with an early-morning overview of the previous shifts, including a weekend summary every Monday.

At the same time, over 50 process values are continuously monitored, with any tolerance violations displayed in an event ticker — a valuable tool for shop floor management and ongoing process optimization.

Full transparency across processes

in data, images, and events

Increased plant availability

thanks to faster response to disturbances

Successful integration

into the LEAN framework

Significantly improved fault analysis

through time-synchronized image and process data

More efficient decision-making

through standardized reports and automatically calculated KPIs

Without ibaCapture, fault analysis would be impossible for us. The iba system has become indispensable for our continuous process optimization.

Sascha Noreikat
Head of Production Cold Rolling, Thyssenkrupp Steel

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.