How can globally distributed production plants be centrally monitored and analyzed?

Centralized monitoring requires consistent acquisition and aggregation of process data across all sites. With ibaPDA, local data is captured and stored centrally in ibaHD-Server. ibaAnalyzer then enables cross-site analysis and comparison. This provides a unified view of all plants and their performance.

How can production processes be standardized and compared across multiple locations?

The foundation for comparability is the definition of standardized KPIs and analysis models for all plants. With ibaAnalyzer, identical KPIs can be calculated and systematically compared. The underlying data is acquired via ibaPDA, while ibaHD-Server ensures long-term availability. This enables reliable benchmarking and targeted optimization measures.

How can historical and live data be used to predict product quality?

By combining historical data with current process values, predictive models for quality forecasting can be developed. ibaHD-Server provides the required historical data, while ibaAnalyzer is used for model creation and evaluation. Continuous model updates enable precise predictions at short intervals. This allows process parameters to be adjusted proactively.

How can flexibility in production be increased through data-driven analysis?

High flexibility requires fast and well-informed decisions during product changes and process adjustments. With ibaAnalyzer, the impact of parameter changes can be quickly evaluated. The underlying data is acquired via ibaPDA and stored in ibaHD-Server. This enables more frequent and efficient production adjustments.

How can time and cost savings be achieved through centralized data analysis?

Centralized data analysis reduces redundant evaluations and accelerates decision-making processes. With ibaHD-Server, all relevant data is centrally available, while ibaAnalyzer enables rapid interpretation. ibaPDA ensures a consistent data foundation across all plants. This minimizes analysis effort and increases efficiency in both operations and optimization.

Process Optimization in Wood Processing

Globally Distributed Plants, One Monitoring Point

As the legacy system no longer met the requirements, the company Kastamonu Entegre looked for a new way to acquire and analyze data for the wood processing industry. After the test in one production line, the iba system was rolled out further and further and has meanwhile been installed in numerous plants distributed all over the world.

About the Project Business Benefits The Technology Used Functions More Success Stories

Central Process Control and Analysis of Different Plants With the iba System

Thanks to the collection of all acquired values at headquarters with ibaPDA, ibaAnalyzer and ibaHD-Server, the global player can monitor and compare the plants across borders and centrally and thus make optimizations. This saves time and money.

In addition, since data from more than one and a half years is available in the ibaHD-Server, highly precise laboratory models for the various production steps can be created in a short time – about every five minutes. With the help of these “Predict Laboratory Models,” the effects of different process parameters on product quality can be predicted and thus optimized. Since this evaluation was very time-consuming for Kastamonu Entegre before using the iba system and results were only available after about three hours, the same product had to be produced for 50 to 60 hours in the past. In the meantime, product changes take place in the plant two to three times a day. This means that products can be better aligned with the corresponding requirements and quality can be increased.

Central overview

of measurement data from all plants

Improved flexibility

of production

Savings

in time and money

The Technology

The data acquisition within the individual plants is realized with ibaPDA. Here, data recorded directly via Ethernet as well as PLC and bus signals recorded with ibaBM or ibaPADU modules are combined and made available to the operating personnel in ibaAnalyzer. The access can be done directly or remotely, the measured values are also stored in ibaHD-Server. To be able to better compare the processes within the individual sites, the identical characteristic values are calculated in ibaAnalyzer for each plant and then sent to the headquarters. This is where the central monitoring takes place. To create quality prediction models, nine monitoring parameters were defined. Based on historical data and recorded live data from the process, the evaluation takes place, based on which the product properties can be reliably predicted. Due to its success, each new plant of Kastamonu Entegre is usually equipped with the iba system.

Schematic illustration of wood processing

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

With the iba system, optimization potentials are revealed and therefore numerous improvements are carried out. The customer thus saves resources and money in the long term.

Ahmet Kösereisoğlu
Project Consultant and Lead Engineer, iba Turkey

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 globally distributed production plants be centrally monitored and analyzed?: Centralized monitoring requires consistent acquisition and aggregation of process data across all sites. With ibaPDA, local data is captured and stored centrally in ibaHD-Server. ibaAnalyzer then enables cross-site analysis and comparison. This provides a unified view of all plants and their performance.
How can production processes be standardized and compared across multiple locations?: The foundation for comparability is the definition of standardized KPIs and analysis models for all plants. With ibaAnalyzer, identical KPIs can be calculated and systematically compared. The underlying data is acquired via ibaPDA, while ibaHD-Server ensures long-term availability. This enables reliable benchmarking and targeted optimization measures.
How can historical and live data be used to predict product quality?: By combining historical data with current process values, predictive models for quality forecasting can be developed. ibaHD-Server provides the required historical data, while ibaAnalyzer is used for model creation and evaluation. Continuous model updates enable precise predictions at short intervals. This allows process parameters to be adjusted proactively.
How can flexibility in production be increased through data-driven analysis?: High flexibility requires fast and well-informed decisions during product changes and process adjustments. With ibaAnalyzer, the impact of parameter changes can be quickly evaluated. The underlying data is acquired via ibaPDA and stored in ibaHD-Server. This enables more frequent and efficient production adjustments.
How can time and cost savings be achieved through centralized data analysis?: Centralized data analysis reduces redundant evaluations and accelerates decision-making processes. With ibaHD-Server, all relevant data is centrally available, while ibaAnalyzer enables rapid interpretation. ibaPDA ensures a consistent data foundation across all plants. This minimizes analysis effort and increases efficiency in both operations and optimization.