Micro-stops
A few seconds at a time, dozens of times per shift. Nobody writes them down, and together they cost more than the breakdown everyone remembers.
MDCplus showsEvery change of machine state with its time.
Read about micro-stops- Main
- Industries
- Automotive
MDCplus for Automotive
Automotive · takt time
Machine monitoring for automotive manufacturing
A line is only as fast as its worst minute. MDCplus shows every stop, changeover and slow cycle on every machine as it happens, so you protect takt time during the shift instead of explaining the shortfall after it.
Line 1 · serial line
Click a station to stop it
Parts out0
Takts lost0
Current stop00:00
Simulation of a serial line, not customer data. In MDCplus every real stop is recorded with its time and reason.
- Every stop with time and reason
- CNC, PLC lines, robots, presses
- Read-only connection
- On premise, also offline
Machine monitoring for automotive means collecting machine data automatically so you can see utilization, stops, cycle time against takt, changeovers and scrap on every machine of a line. In high-volume production a stop on one station often stops the whole line, so the value is in seeing losses the moment they start and in knowing which station really sets the pace.
Where takt is lost
Five losses that decide whether the line makes its number
Changeovers between variants
Mixed models and variants mean frequent changeovers. If setup time is not measured, it quietly grows.
MDCplus showsSetup as its own state, with time per changeover.
SMED templateTool changes and tool wear
A worn tool slows the cycle or damages the part, and a changed tool stops the machine. Both are visible only if the data is collected.
MDCplus showsTool data from the controller where available, plus vibration diagnostics.
Tool wear and OEEWaiting
For material, for a person, for the station before. These stops look small on the machine and large on the line.
MDCplus showsStops with a reason the operator selects, ready for a weekly Pareto.
Downtime ParetoRunning slower than takt
The machine is running, so nobody reacts, yet every part takes a little longer than planned.
MDCplus showsActual cycle time per part against the plan.
Cycle time and throughputFind the pace-setter
One station sets the speed of the whole line
If one station needs longer than takt, every other station waits for it. Improving a station that is not the bottleneck does not make the line faster. With the actual cycle time of every machine on one screen, you can see which station sets the pace before you spend money on the wrong one.
Bottleneck logic that saves capital
Illustration, not customer data.
One data source, three screens
What each person on the floor and in the office gets
Operator
The floor screen at the line
- Machine states at a glance
- Stop reasons selected in seconds
- Parts against the plan
Supervisor
The phone, anywhere on the floor
- Live states of every machine
- Which station is stopped now, and why
- Parts per shift or operator
Plant manager
Reports and the weekly review
- OEE, downtime and scrap reports
- More than 100 report and graph templates
- Data to ERP and MES through the API
The ideal rollout
Start where the line is slowest, then widen
- Connect the bottleneckRead-only. The first machine is connected within 1 to 2 hours.
- Put states on the floor screenRunning, idle, setup, alarm, offline, on screens and on mobile.
- Name the stopsOperators select a reason, so stops become a usable Pareto.
- Measure changeoversSetup time per changeover shows where SMED pays off.
- Add tool wear and maintenanceTool data, vibration diagnostics, maintenance on real run time.
- Roll out line by lineConnect ERP and MES through the API, then repeat on the next line.
Not only CNC
Machines, PLC lines, robots and presses in one picture
An automotive plant is a mix: machining centers and lathes, press and injection molding machines, robot cells and PLC-controlled lines. MDCplus connects to all of them over more than 100 open protocols, read-only, and shows them in the same screens and reports. A PLC line is connected through its PLC, and one PLC or HMI counts as one data collection point.
It is installed on premise and can run fully inside a closed network without internet access, which suits plants with strict IT or customer security rules.
Open the machine connectivity checker to see the connection route for your controller.
Brief us on your line
Tell us the machines, the takt you work to and where the line loses time. We will answer what can be read and what a sensible first step looks like for your plant.
Frequently asked questions
What should an automotive plant monitor first?
Start with the bottleneck station and the stations around it: machine states, stop reasons, cycle time against takt and changeover time. These show where the line loses time. Tool wear and maintenance come next.
Can MDCplus show micro-stops?
It records every change of machine state with its time, so short stops appear in the data even when operators do not log them. A short stop that repeats many times per shift is often a larger loss than one long breakdown.
Does it work with PLC-controlled lines and robots, or only CNC machines?
It works with CNC machines, PLCs, robots, presses and injection molding machines. A line controlled by a PLC is connected through the PLC, and one PLC or HMI is counted as one data collection point for licensing.
Is MDCplus a MES?
No. MDCplus collects and reports machine data: states, stops, cycle times, counts and scrap. It can send this data to a MES or ERP through the API. It does not replace your MES or your quality system.
Can it run in a closed network?
Yes. MDCplus is installed on premise and can work fully inside a closed network without internet access, which suits plants with strict IT or customer security requirements.
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
- Most used digital solutions in automotive
- Invisible micro-stops that bring your OEE down
- How andon reduces downtime in production
- Downtime Pareto principle with a free template
- Late starts and early stops: how to fix them
- SMED changeover template in Excel
- How to calculate cycle time and throughput
- Bottleneck logic: when to stop chasing OEE grades
- CNC tool wear offsets and OEE
- OEE: the complete production KPI guide
Other industries
AerospaceComing soon
Railway componentsComing soon
Turbines & PistonsComing soon
Equipment manufacturingComing soon
Precision machiningComing soon
Job shopsComing soon
Contract manufacturingComing soon
Process manufacturingComing soon
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.
