Process Signals

What Are Process Signals?

Process signals are data points captured in real-time from machines and equipment – such as temperature, pressure, vibrations, or flow rates. They reflect the condition and performance of production processes and are closely linked to production performance indicators. High production stability and strong production management benefit directly from their analysis and use.

Why Are Process Signals Important?

Process signals provide transparency about the manufacturing process and enable early detection of deviations, such as machine failures or material shortages. They help reduce manufacturing costs by minimizing process interruptions and quality losses. Without these signals, production remains reactive rather than proactive, leading to higher scrap costs and rework.

Applications of Process Signals

• Error detection: Signals warn of deviations that require disruption management.
• Maintenance planning: Vibrations or temperature increases indicate wear and support Predictive Maintenance.
• Process optimization: Data such as cycle times show potential for shorter setup processes or better utilization.

Through their analysis, companies can specifically address weaknesses and increase efficiency.

Measures for Using Process Signals

A preventive maintenance strategy uses signals to avoid failures and increase equipment availability. Optimized production planning adjusts processes based on real-time data to reduce bottlenecks. Process monitoring in combination with Manufacturing Execution Systems (MES) processes signals and enables immediate reactions. Training for employees promotes understanding and use of this data in everyday operations.

Technological Support

Manufacturing Execution Systems (MES) collect and analyze process signals in real-time to make precise decisions. Sensors and IoT technologies continuously provide data that enable process monitoring. Predictive Maintenance uses signals to predict maintenance needs and avoid downtime. These technologies make process signals a central tool for modern manufacturing.

Conclusion: Process Signals as a Success Factor

Process signals are the key to efficient and stable production.

Through their targeted collection and analysis, companies can optimize their processes, reduce costs, and ensure quality.

Start by integrating process signals into your monitoring systems and use the data to improve your manufacturing.