A new app from Coventry-based Bystronic UK Ltd (www.bystronic.co.uk) monitors in real time all processes taking place on its machines, which include laser cutters, press brakes and water-jet cutters.

Called ByCockpit, the app evaluates collected data and generates status reports, thus supporting the networking requirements of Industry 4.0.

Running on a laptop, smartphone or tablet, ByCockpit generates reports while the machines are producing parts, providing immediate feedback so that action can be taken as necessary. One report is the ‘sunburst’ view, which displays the status of the factory at a glance.

Green bars indicate machines that are currently in operation, while a red bar signifies idle time. Tapping on the screen switches the app from the sunburst view to, for example, the cutting overview for a ByStar fibre laser.

The status window (one of six process-related windows) shows power output, total machine operating hours and whether maintenance is due. Furthermore, a performance window quantifies the efficiency of the ByStar’s production, making it easy to see if processes are not running optimally, while other windows show where problems lie.

The app’s material performance window displays the quantity of usable parts that have been cut and the amount of waste, while the machine availability window breaks down run times, idle times and changeover times.

If idle times are too long, another window provides information about the cause. To monitor press brake performance, the bending symbol is selected. The ratio between the number of parts produced and the number of tool changes is an important parameter.

If the number of tool changes is too high, overall production time increases, affecting productivity. All this information is provided in the performance window.

Meanwhile, the warehouse symbol reveals how many tonnes of aluminium, stainless steel, mild steel, copper or other materials are in stock, enabling timely re-ordering. ByCockpit also calculates the purchase value of the raw materials.

All Bystronic’s latest-generation machines are ready to be connected to ByCockpit. A connectivity kit is installed as a gateway to each machine, which also acts as a firewall (via this connection, machine data is collected, encrypted and sent to a cloud server).