ZenkertSystems · 0 sites · 0 plants
A factory that runs — and can back up every number
No dashboard and no slides: a complete plant in continuous operation, from the holding register of a 1998 machine to the euro figure for senior management. Every number on this page comes with the command beside it that you can use to recompute it.
Five plants in continuous operation · OPC UA, Modbus, Sparkplug B · Asset Administration Shell on 29 assets · 245 tests · available around the clock
I run a manufacturing operation
Your oldest machine has no interface. It can count. That is enough.
Almost every controller gives up counter readings, even one from 1998. From those comes a complete OEE per ISO 22400 — calculated at the edge, without touching the controller and without a new machine.
15 holding registers are enough. The band saw in this factory gets within half a percentage point of its machine’s true value.
Which problem do you have? →I build machines
Your customer demands an Asset Administration Shell. Your engineering data already has most of it.
Topology, interfaces and roles are in EPLAN or TIA. AutomationML lets you read them in, instead of reconstructing them in interviews with maintenance — the longest part of any integration.
134 property identifiers at property level, not at submodel level. Nameplate per IDTA 02006-2-0, read out rather than asserted.
What you have to deliver →Under laboratory conditions
± 1
cut prediction error of tool life, on average
With realistic noise
± 30
cuts — measured, not estimated
Both figures are on this page, with the script to recompute them. We publish the second one voluntarily because it would come out in operation anyway — the only question is whether it comes from the vendor or from a disappointed customer.
Intro call
90 minutes, and you leave with a list rather than an impression.
If you manufacture: which of your machines can deliver a
reliable KPI without modification — and which cannot.
If you build machines: what your engineering data
already yields for an Asset Administration Shell, and what is really missing.
You bring what you have: a machine list, a photo of the control cabinet, a screenshot of the controller, an EPLAN or TIA export. We go through it. At the end there is a list with three columns — works immediately, works with effort, doesn’t work — and the reason for every entry.
What it is not: a demo followed by a quotation. The demo is already here, around the clock, and you don’t need me for it.
Everywhere on this interface it says how reliable the number underneath is. What belongs to the next stage of expansion is drawn dashed. What an intervention achieved is recorded as a measurement in the evidence ledger, not as a promise. That is the test you should apply to every demo: whoever doesn’t state their limits hasn’t measured them.
Five plant types under one model — a chained production line, a parallel CNC cell, a high-speed filling line, a batch process plant and a machine from 1998 that only speaks Modbus. They share a nameplate and technical data and nothing else; a cell has no cycle, a reactor has no piece count, and the band saw doesn’t compute its own OEE — the connector at its side does. The cross-check is on Data paths, Technology and Model.