How can production data be efficiently stored and retrieved over multiple years?

Long-term data storage requires a scalable system with direct access to historical data without complex archiving processes. With ibaHD-Server, process data can be continuously stored over many years and accessed instantly. Navigation is time-range based, enabling targeted analysis with just a few clicks. This allows for fast comparisons and significantly reduces data retrieval effort.

How can historical process data be used for quality assurance and complaint analysis?

Reliable quality assurance requires complete documentation of all relevant process parameters. ibaPDA continuously acquires all necessary signals, which are stored long-term in ibaHD-Server. In case of complaints, this data can be specifically analyzed and compared with reference values. This enables production conditions to be clearly reconstructed and validated even years later.

How can continuous processes with long cycle times be effectively monitored?

Processes with long residence times require an adapted data acquisition strategy with appropriate sampling intervals. With ibaPDA, flexible sampling rates can be defined and adjusted to the dynamics of the process. The data stored in ibaHD-Server then enables analysis of temperature, speed, and process trends over extended periods. This allows even slow-developing deviations to be detected at an early stage.

How can data volume be efficiently managed in long-term recording scenarios?

An efficient data strategy combines suitable sampling rates with event-based acquisition. ibaHD-Server enables targeted storage of relevant data while avoiding unnecessary data volume. In combination with ibaPDA, data acquisition can be optimized to maintain a balance between storage requirements and analytical capability. This is particularly important for multi-year data storage.

How can historical data be used for long-term process comparison and optimization?

Long-term data provides the foundation for meaningful comparisons between different production periods. With ibaHD-Server, historical signal trends can be quickly visualized and compared. In combination with ibaAnalyzer, detailed evaluations can be performed and the root causes of deviations identified. This supports continuous process improvement as well as compliance with quality requirements.

“With ibaHD-Server, we have direct access to seven years of historical data”

Success Story

What began seven years ago with the replacement of paper chart recorders in a pusher-type furnace has evolved into a key pillar of quality assurance at the Annahütte steel mill: today, the installed iba system records around 4,800 signals.

About the Project Effortless Access Quality Assurance Used Functions More Success Stories

Turning Data Mountains into Digital Insight

Mountains of data once stored on kilometers of paper rolls. To move away from this outdated form of quality assurance and data acquisition, Annahütte opted for an iba solution in one of its pusher-type furnaces about seven years ago.

“We’ve been using ibaHD-Server almost unchanged since its introduction. Even back then, we found a solution that we are still very satisfied with today,” says Konrad Kern, who is responsible for quality assurance and measurement data acquisition at the manufacturer of bar and threaded steel products. Annahütte now records around 4,800 signals using ibaPDA across three pusher furnaces, a hot rolling mill, and a hydroelectric power plant, storing the data in the ibaHD-Server.
“The data from the pusher furnace is particularly relevant for production management, since the products remain in the furnace for a long time. We can monitor whether the temperature profile is consistent, the speed is correct, and whether the furnace reacts properly to adjustments,” Kern explains. Undetected fluctuations in process parameters could, in the worst case, result in scrapping material that was produced with great effort.

Annahuette Rolling Mill from a bird’s eye view

Effortless Access to Years of Measurement Data

Annahütte has opted for a recording interval of 200 milliseconds for data acquisition. This is more than sufficient for ensuring product quality: “Our pusher furnace is 200 meters long, and the product takes 48 hours to pass through it. Because of the slow movement, we don’t need extremely high-resolution data,” says Kern.

ibaPDA allows for time bases ranging from 1 to 1,000 milliseconds, and for higher signal dynamics, special modules can acquire data in intervals as short as 10 microseconds. Thanks to the long-term recordings, Annahütte ensures sustainable quality assurance – even years after production. “With just one click in the visualization calendar, we can access comparative data and identify the causes of differing product properties. And in case of complaints, we can prove that there were no production issues on our end. For the automotive industry, for example, we retain this data for 10 to 15 years,” explains the certified electrical engineer.

The volume of data is no problem for ibaHD-Server: “We handle this with event-based recording, so the data volume is really just peanuts,” Kern says with a smile. “When I need data and know the time range, it’s incredibly simple. I select the date and instantly have the data I need at my fingertips. It’s fast, flexible, and that’s always been one of the things I’ve appreciated most about the HD-Server.”
Apart from the annual maintenance and update work to integrate new signals, the ibaHD-Server runs continuously and without interruption at the Annahütte steel mill.

When I need data and know the time range, it’s incredibly simple. I select the date and instantly have the data I need at my fingertips.

Konrad Kern
Quality Assurance and Data Acquisition, Annahütte

The iba System Makes a Lasting Contribution to Quality Assurance

Whether for rock anchors or steel beams for high-rise buildings – documenting the strength and corresponding process data is essential at the Annahütte steel mill. The implemented iba system enables continuous data acquisition, comparison with historical values, and long-term analysis. This not only allows early detection of deviations: ibaHD-Server also facilitates reliable proof of compliance with (customer) requirements – even years after production – with just a few clicks. For the past seven years, the iba system has thus formed the foundation of quality assurance at the plant – reliably and without interruption.

Test the iba System Now!

Download the demo of ibaPDA and ibaAnalyzer and start optimizing your processes today. Try it free of charge for 30 days!

Request a ibaPDA-Demo License

Used Functions

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

Explore More Success Stories

Read more inspiring success stories of our satisfied customers.

Frequently Asked Questions (FAQ)

How can production data be efficiently stored and retrieved over multiple years?: Long-term data storage requires a scalable system with direct access to historical data without complex archiving processes. With ibaHD-Server, process data can be continuously stored over many years and accessed instantly. Navigation is time-range based, enabling targeted analysis with just a few clicks. This allows for fast comparisons and significantly reduces data retrieval effort.
How can historical process data be used for quality assurance and complaint analysis?: Reliable quality assurance requires complete documentation of all relevant process parameters. ibaPDA continuously acquires all necessary signals, which are stored long-term in ibaHD-Server. In case of complaints, this data can be specifically analyzed and compared with reference values. This enables production conditions to be clearly reconstructed and validated even years later.
How can continuous processes with long cycle times be effectively monitored?: Processes with long residence times require an adapted data acquisition strategy with appropriate sampling intervals. With ibaPDA, flexible sampling rates can be defined and adjusted to the dynamics of the process. The data stored in ibaHD-Server then enables analysis of temperature, speed, and process trends over extended periods. This allows even slow-developing deviations to be detected at an early stage.
How can data volume be efficiently managed in long-term recording scenarios?: An efficient data strategy combines suitable sampling rates with event-based acquisition. ibaHD-Server enables targeted storage of relevant data while avoiding unnecessary data volume. In combination with ibaPDA, data acquisition can be optimized to maintain a balance between storage requirements and analytical capability. This is particularly important for multi-year data storage.
How can historical data be used for long-term process comparison and optimization?: Long-term data provides the foundation for meaningful comparisons between different production periods. With ibaHD-Server, historical signal trends can be quickly visualized and compared. In combination with ibaAnalyzer, detailed evaluations can be performed and the root causes of deviations identified. This supports continuous process improvement as well as compliance with quality requirements.