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MDCplus for Aerospace
Aerospace · machine data
Machine monitoring for aerospace manufacturing
Long cycles, expensive material and strict documentation mean that every minute of a machine's state matters. MDCplus shows what each machine is doing in real time and keeps the history, so problems are found while the part can still be saved.
- Real-time machine states
- FANUC, Siemens, HEIDENHAIN, Okuma, Mazatrol
- Read-only connection
- Closed network possible
Machine monitoring for aerospace means collecting machine data automatically, so you can see utilization, stops, cycle times and scrap for every machine and every part, with a history you can show in an audit. Aerospace parts are expensive, cycles are long and a late failure costs a lot, so the value is in catching problems early and in knowing exactly where machine hours are lost.
Life of one part
What the machine data tells you, from release to record
- 01 · ReleaseThe right program on the right machine
NC program management shows which program is loaded on which machine, so the record of what was machined with what starts complete.
- 02 · SetupSetup time is counted, not guessed
Setup is its own machine state. You see how long each part really needs before the first cut.
- 03 · CutA long cycle, watched live
Running, idle, alarm or offline in real time, with the stop reason and the time of every stop.
- 04 · Tool and spindleWear shows before scrap does
Tool data from the controller where it is available, plus vibration monitoring and diagnostics on the spindle.
- 05 · CountGood and scrapped parts
Part counts and scrap entries per machine, shift and operator, compared with the plan.
- 06 · RecordHistory you can show in an audit
Machine states over time, linked to orders in ERP or MES through the API. It supports your quality system and does not replace it.
Why long cycles change the maths
A stop in the middle of a cycle is a stop you can still act on
A cycle on an aerospace part can run for many hours. If the alarm is found at the end of the shift, the hours after it are lost and the part may be too. With live states and stop reasons, the person responsible sees the stop when it happens, while there is still something to save.
Illustration of one long cycle on one machine. Not customer data.
Four requirements aerospace production puts on machine data
Long cycles, expensive parts
A stop or an alarm late in a long cycle can scrap a part that carries hours of machine time and costly material. You need to know the moment a machine leaves its normal state and why.
- Machine state in real time
- Alarms and stop reasons with time
- Cycle time per part, scrap
Hard materials and tool condition
Hard-to-machine alloys wear tools quickly, and a broken tool or a spindle problem means scrap and unplanned downtime. Early signs are worth more than a report after the fact.
- Tool data from the controller where it is available
- Vibration monitoring and diagnostics
- Maintenance planning on real run time
Traceability and audit records
Audits ask what ran on which machine, when, and with which program. Machine data gives you the time record, and the program management module shows which NC program is on which machine.
- History of machine states
- NC program management (DNC)
- API to ERP and MES for the order context
Capacity, setups and on-time delivery
Small batches mean many setups, and machine hours are usually the bottleneck. Knowing real setup time and real utilization is what makes delivery dates and quotes reliable.
- Setup time per part
- Utilization and parts per shift or operator
- Machine hour rate from real hours
Pre-flight checklist
What an ideal setup looks like, in the order we would do it
- Check 01Connect the machines read-onlyThe first machine is connected within 1 to 2 hours. Machines with an Ethernet interface need no additional hardware, and older ones connect through a terminal, PLC signals or sensors.
- Check 02See states and stop reasons liveEvery machine shows running, idle, setup, alarm or offline on floor screens and on mobile, and every stop gets a reason.
- Check 03Measure cycle time and scrap per partActual cycle time and scrapped parts are compared with the plan, so a drifting process shows up before the next batch.
- Check 04Know which program runs whereProgram management keeps track of the NC programs on the machines, so the record of what was machined with what is complete.
- Check 05Feed the data to ERP and MESThrough the API, order context goes in and actual results come back. More than 100 report and graph templates cover management and audit needs.
- Check 06Add maintenance and vibration monitoringWhen the basics work, add the computerized maintenance module and vibration diagnostics on the machines where unplanned stops cost the most.
The instrument panel: six questions and where the answer comes from
Where are the machine hours lost?
- Data
- Machine states and stop reasons
- Report
- Utilization and downtime report
How long does a part really take?
- Data
- Cycle start and end
- Report
- Cycle time per part
How much is scrapped, and when?
- Data
- Part counts and scrap entries
- Report
- Scrapped parts report
Which setups take too long?
- Data
- Setup state
- Report
- Setup time per part
What was produced per shift or operator?
- Data
- Shifts and operators
- Report
- Parts per shift or operator, operator effectiveness
Is a machine drifting toward failure?
- Data
- Vibration and spindle data
- Report
- Vibration monitoring and diagnostics
Mixed machine park · closed network
Connecting a mixed machine park
Aerospace shops usually run several generations of controllers side by side. MDCplus supports FANUC (FOCAS 2), Siemens Sinumerik (OPC UA or the native interface), HEIDENHAIN (LSV2 / DNC), Mazatrol, Okuma OSP and Haas, plus PLCs and legacy machines, over more than 100 open protocols in total. For defense and other critical production, MDCplus is installed on premise and works fully inside a closed network without internet access.
- FANUC FOCAS 2
- Siemens Sinumerik
- HEIDENHAIN
- Okuma OSP
- Mazatrol
- Haas
- PLC and legacy
Open the machine connectivity checker to see the connection route for your controller.
Brief us on your part
Name the part family, the machines and their controllers, and where the hours are lost. We will answer what can be read and what a sensible first step looks like for your aerospace shop.
Frequently asked questions
What should an aerospace manufacturer monitor first?
Start with machine states and stop reasons, cycle time per part, scrap and setup time. These four show where machine hours are lost. Maintenance and vibration monitoring come next, on the machines where an unplanned stop is most expensive.
Can machine monitoring help with audits and traceability?
Yes, as a source of data. It records machine states and programs over time and, through the API, can be linked to orders in ERP or MES. It does not replace your quality management system or certification requirements.
Can MDCplus work without internet access for defense work?
Yes. MDCplus is a full on-premise system that runs in a closed network with no internet access, which makes it suitable for defense and other critical production.
Does it work with 5-axis and older machines?
It connects through the controller, so the question is the controller and its version, not the number of axes. Check your machine in the connectivity checker. Older machines connect through a terminal, PLC signals or additional sensors.
How quickly can we start?
The first machine is connected within 1 to 2 hours. The rest depends on how fast you provide the list of machines and the network access on the site.
How is MDCplus licensed?
MDCplus is a perpetual license per data collection point, where one PLC or HMI is one license. The price includes implementation and the server license.
Technical library
Read more
- Why machine data collection is crucial for the aerospace industry
- 5-axis machining and its benefits
- CNC tool wear offsets and OEE
- CNC tool breakage: causes, detection and prevention
- Practical tools to detect spindle issues
- Reducing CNC scrap with in-process inspection
- HEIDENHAIN DNC interface
- SMED changeover template in Excel
Other industries
Free tools
- Machine connectivity checker: find the connection route for your controller.
- Machine hour rate calculator: cost of a scheduled and a productive hour.
- Digital maturity assessment: 20 questions across 7 areas in about 5 minutes.
- Product overview, FAQ and all industries.
Last updated: . Prepared by the MDCplus team.
