Industry 4.0 Software: Empowering Service Specialists to Boost Machine Availability

Fulfilling the Need to Efficiently Improve Machine Availability

Last week I spoke with a production manager overseeing a plant with 500 employees and 150 machines from multiple vendors and production years. He wanted to know whether Industry 4.0 solutions could raise machine uptime and help his service technicians without adding complex programming tasks.

For machines equipped with Rexroth control systems, I demonstrated a solution that works instantly. Open Core Engineering (OCE) provides software functions that access IndraMotion control units directly—no extra PLC code is required, and the functions run in parallel with the existing PLC.

The first step is for the control systems to send real‑time data on component operating states. OCE’s interface streams this information to the software for rules‑based analysis, eliminating the need for technicians to manually pull data from each machine.

Maintenance Technicians Lead the Shift Toward Predictive Maintenance

Raw data alone is insufficient; it must be converted into actionable rules. The Production Rules Configurator allows technicians to encode their expertise—such as recognizing that a change in engine torque signals wear—into executable rules.

Previously, technicians would inspect each machine and retrieve data individually—a tedious process. Now, a rule like “if torque changes by X, notify maintenance” triggers an automatic alert, freeing technicians from manual checks and ensuring timely intervention.

These rules use tolerance thresholds and trend analysis to spot deviations promptly, enabling dynamic adjustment of service intervals. By aligning maintenance with actual wear, companies can significantly cut unnecessary work and costs. Importantly, the rules integrate seamlessly into existing IT systems and can be modified by technicians on the fly, even while the machine is running.

A Digital Assistant That Boosts Flexibility and Speed

The rule engine essentially acts as a digital assistant, guiding skilled staff to make the right decisions at the right time. The production manager, initially skeptical, saw the benefits when a service technician defined rules on a PC—no programming required and no PLC touch.

While maintenance is a primary use case, rule‑based analysis can link machine operating data to business processes across many production scenarios, all without altering the machine program.

What other applications could you envision for rule‑based analysis and support in production?