DISPATCHER: Software & Hardware Complex Solution for continuous real-time monitoring of production equipment and preparing various reports on its states and events.

www.intechnology.ru lan@cncinfo.ru
RELIABLE SYSTEM FOR INDUSTRIAL
PROCESS MONITORING
DISPATCHER monitoring system is easy to incorporate into any enterprise infrastructure. It helps in getting
objective information on loads, downtime, technology, mean time to failure for each piece of equipment.

Objectives – higher operating efficiency of process equipment, improved
industrial productivity.
Objectives and problems of Dispatcher
http://www.intechnology.ruhttp://www.intechnology.ru
Control
Analysis
Planning
Implementation
• Monitoring of productive
machinery, equipment and
operating personnel
• Downtime management
• Centralized distribution of control
programs for NC machine tools
• Production task control
Dispatcher – automated information system for online monitoring of production machinery and personnel at the enterprise

Arrangement of controlled equipment
Direct connection via LAN Unified connection via I/O terminals

Direct connection via standard
NC interfaces.
Connection via I/O terminal. Connection via Terminal
registrator «TR-05»
.
• Automated monitoring of machine tools states (machine turned on, production on, emergency etc.);
• Monitoring of downtime causes (types) and service personnel call-up;
• Control of process technological parameters and detection of irregularities;
• Calculating power consumption and power factor (cos ϕ) in various work modes;
• Loading control programs to NC control blocks through various interfaces.
Any industrial equipment can be connected by terminals
Hardware for AIS «Dispatcher»

Software for AIS «Dispatcher»
• Server software
• Client software

AIS «Dispatcher» advantages
Monitoring of equipment
and personnel
We can connect any NC
machine tools and universal
equipment of any make and
age
Direct connection to
Numerical Control by
Fanuc, Siemens,
Heidenhain, BaltSystem,
Mayak, Okuma, Haas
Mobile
monitoring
Integration with MES,
ERP, PDM
1C, Prisma, Galactica,
Windchill, SPRUT-technology,
Technoclass
Mobile panel for
monitoring

AIS «Dispatcher» - clients
More than 40 enterprises use «Dispatcher»

BEFORE AFTER
Machine model V40L V60i Matek V40L V60i Matek
Machine tools characteristics Machine tools characteristics
Quantity 4 6 4 4 6 4
Machine cost, thousand
rubles
6,458 9,112 41,191 6,458 9,112 41,191
Dispatcher cost, thousand
rubles
- - - 323 456 2,060
Total cost, thousand rubles 25,832 54,672 164,764 27,124 57,406 173,002
Performance Indicators Performance Indicators
Machine tool utilization
factor (Ки)
0.38 0.38 0.38 0.56 0.56 0.56
Worktime fund, hours 1,508 1,508 1,508 2,222 2,222 2,222
Machine tools maintenance cost Machine tools maintenance cost
Total annual cost, thousand
rubles
6,401 12,462 29,641 6,617 12,918 31,014
Cost per operator hour,
roubles
1,061 1,378 4,914 744 969 3,489
Annual cost advantages, thousand rubles 704 908 3,167
Total savings per workshop section,
thousand rubles
4,779
Workshop section with 14 machine tools had utilization factor 0,38 before
installation of Dispatcher. Due to application of Dispatcher the said factor has
grown as great as 0,56. Dispatcher also brought about 4,8 million rubles of annual
savings , that is 10% of yearly costs.

http://www.intechnology.ru
Business case shows short pay-off period and significant economic benefit for
client enterprise
-1
-0,5
0
0,5
1
1,5
2
2,5
year 1 year 2 year 3 year 4 год 5
M$
Profits
Investments
Project economics
NPV 5M $
IRR 498%
Payback period
6
months.
At discount rate 12%
Economic benefit for client enterprise
Revenues, 2014 72.3M $
Total profit, 2014 22.2M $
Machine tools quantity 100
Effective load increase of machinery equipment 10%
Economic benefit = Total profit increase
22.2М*10% =
2.22М $
Startup/implementation costs
Machine tool connection hours of labour 1 man-hours
1 man-hours of connection cost 148$
1 man-hours of software setup/implementation cost 296$
Cost of connecting 100 machine tools (+T&E) 29.5 thous.$
Cost of software setup/implementation, 200 man-
hours (+T&E)
88.6 thous.$
Cost of blocks for 100 machine tools (2 blocks per
machine tool)
49.2 thous.$
Total 167.3 thous.$
Software subscription per
machine tool a year = 2300 $

A gear-reduction box & power transmission production plant
-10
0
10
20
30
40
50
60
year 1 year 2 year 3 year 4 год 5
Mrubles
Profit
Investment
Project economics
Payback period 6 мес.
At discount rate 12%
Economic benefit
Machine tools monitored by AIS Dispatcher 76
Acquisition and setup/implementation cost
5,7 million
rubles
Period of utilization since implementation 18 months
Average machine hour cost 2000 rubles
Effective load increase of machinery equipment 6%
Additional benefit
Effective project planning taking into account actual equipment load
and actual hours of labour for technological operations
Regular equipment load
Reduced risks of production breaks
Computerized support for service and dispatching departments
(reduced downtime)
Software subscription per year = 1 million rubles
Total annual savings per workshop section 55 million rubles
.
+ 4,7 million euros were reassigned to other investment projects
instead of buying new equipment previously planned

Current project cases
One recent example of a large enterprise. At first it had equipment utilization factor 14%, then raised
to 19% in just one year. Not much of a growth, but better usage of machinery made it possible to
eliminate Saturday work shifts. Without proper control some workers could have their machine tools
turned on while they were out smoking. Monitoring diagrams revealed such unjustifiable breaks –
one could see equipment in on state but no programmed work was done. Energy was being
consumed, salaries were paid, supporting and service teams were busy working, but with little
effectiveness. Changes succeeded and overall performance increased by 5%. Working Saturdays
were excluded. …
At another enterprise monitoring system was installed in two workshops. Machine tools were used in
two work shifts, but often production plans were not accomplished. Perspective plans were
scheduled till 2020 year. Monitoring data analyses showed possible means of optimization that
shortened the schedule by 2 years. Economic benefit for 10 machine tools can easily be evaluated…
Client 1
Client 2

Client software structure of AIS «Dispatcher»
Option
«Power consumption
monitoring»
Option
«Efficiency Panel»
Option
«Video monitoring»
Option
«Report Generator»
Option
«Mobile panel for
monitoring»
Option
«Collective panel for
monitoring»
Module
«Production control»
Module
«Downtime management»
• Downtime management (DTM) subsystem
• Total productive maintenance (TPM)
subsystem
Module
«Numerical control programs
management»

Integrating AIS «Dispatcher» with…
Successful integration with PDM (WindChill), 1С, PRIZMA, MES «Technoclass» etc.

LLC Innovative Center StankoService
Address : 214000, Smolensk, Carl Marx street, 12, 3-rd floor, room 17
Telephone : (4812) 24-41-02, 69-09-10
E-mail: lan@cncinfo.ru
Check!
Analyze!
Manage!

DISPATCHER: Software & Hardware Complex Solution for continuous real-time monitoring of production equipment and preparing various reports on its states and events.

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