Shop Floor Data Collection

How Automation Through Direct Machine Interface Can Change the Game For Your Operation

Direct machine interface, often referred to as DMI, allows you to connect directly to all types of production equipment and allows you to view real-time information and historical analysis from anywhere, anytime, using just the web browser on any device.

Why DMI is a Game-Changer For You

Collecting data manually can take a lot of time. By the time you collect the data, it can often be inaccurate and old, leading you to make decisions off the wrong data. But through direct machine interface, your production is completely recorded and monitored in real-time for all your connected machines. For example, if you’re monitoring the progress of orders and machine speed, you can view it in real-time allowing planners to track production live, while providing you with better insights for your business.

Our DMI Solution Built For You

Advantzware’s  solution is an affordable, cost-effective system that helps you improve the productivity of your manufacturing process immediately. Installed in over 700 manufacturing facilities of all types and sizes, has allowed organizations to experience at least 10% improvement in productivity. By collecting, displaying, and transmitting real-time data you have a wealth of information at your fingertips. Connect your operations to any ERP application. Some of the features include:

  • Downtime Tracking: Collect, analyze, and eliminate causes for downtime and rejects
  • OEE Monitoring: Track machine status, analyze, and improve production efficiency
  • Manufacturing Scheduling: Visual production scheduler produces real-world forecasts
  • Preventative Maintenance/TPM: Schedule maintenance based on actual equipment run hours and cycles
  • Production Reporting: Eliminate manual data collection and transcription
  • ERP Interface: Tie master production schedule to shop floor for dynamic scheduling, accurate job completion forecasts, and automatic WIP/inventory updates

How It Works

The ProductionACE solution consists of devices that are able to communicate with all types of equipment. They connect directly to any production machine using existing electrical signals (switches/relays, photo/proximity sensor, so you don’t have to deal with the difficult task of integrating a variety of machines with different communication technologies and protocols. The data is then collected, reported, and displayed directly to a smartphone, tablet, website or back into the ERP system like Advantzware. There are a headless or operator input capable devices enabling you to tailor the system functionality to your operations for deeper insights, real-time performance tracking, and enhanced communication.


  • Headless device
  • Browser-based operator
  • Includes user configurable discrete inputs and user selectable discrete outputs
  • Designed for the shop floor environment


  • Built-in operator interface with water and dust resistance for harsh environments
  • Includes user configurable discrete inputs and user selectable discrete outputs
  • Operator enters reason and selects from 40 downtime and 20 reject types
  • Spoilage and downtime entry


Manage your production, machines, people, and OEE for real-time visibility into any manufacturing process – for a single plant to multi-site operations.


Advantzware’s DMI solution is a proven and affordable system to help you improve productivity of your manufacturing processes. Get immediate and reliable improvement in productivity after installing our DMI solution. Reach out to our dedicated team to see how to integrate into your Advantzware system for more accurate job reporting, job costing, estimating standards, and scheduling.

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Posted by jon in Direct Machine Interface

The Benefits of Real-Time Shop Floor Data Collection

The shift to mobile in the digital era has created an entirely new paradigm for the packaging industry. With increased demand for packaging and consumer’s expectations for sustainability and innovation, packaging companies are turning to digital solutions to save the day. In the industry, time-consuming manual processes and outdated technology have historically prevented businesses from taking the steps needed to meet these new expectations. 

Today, as the packaging industry embraces digital trends, there’s a need for new products and solutions that are developed with you in mind. That’s why the adoption of a modern Shop Floor Data Collection (SFDC) can have far-reaching benefits. From increasing operational efficiencies to streamlining shop floor data, take a look at some of the key benefits of modernizing your shop floor data collection.

The Benefits of Paperless Job Tickets

Using paper for SFDC is not only less efficient and more time-consuming, but also generates a lot of waste. There are a lot of benefits of going paperless – saves time, money, space to name a few. Here are some others.


Fewer Errors

What once was a time-consuming process to gather data is now made much easier with fast data reporting by job with a touch of a finger. Before data collection was automated, collecting data meant spending hours making sure it was entered correctly. Then there were problems with inaccurate, incomplete, illegible, or biased data. Now, with automated processes, you can see accurate, real-time schedule board updates, machine efficiency, and labor costs by job without the headache of costly manual processes.


Up-to-date Information

Companies who rely on paper-based data collection operate on off-dated information, basing decisions off past production data. Oftentimes, these businesses get their data weeks after a production cycle, plan their response, then wait another several weeks to see if the response increased operational efficiency.


Attract New Generation of Employees

The next generation of employees have grown up in the digital age. Accustomed to using modern tools like Google Docs and CRM, younger employees are digital natives who are adept at – and want to use – the latest technology. Using modern technology not only makes the job more appealing, but makes sense operationally to streamline processes and increase efficiency. 


The Benefits of Real-Time Data Collection

Automatic data collection gives you unprecedented visibility into your production operations with real-time shop floor data to increase efficiencies. When you begin to use real-time shop floor data collection, you can easily begin to see the benefits, which include the following:  


Automate and Streamline Data Collection

The ability to centralize data company-wide in real time allows for you to make faster, more effective decisions, while driving growth. With just a press of a finger, an effective SFDC can streamline your data to reduce the possibility for manual data errors. Also, automated data collection significantly decreases record storage costs and the time to retrieve real-time or archived data.


Better Data Quality

Access to quality data empowers you to identify potential errors earlier before they become costly, serious problems. By better understanding the details of the shop floor, you gain a clearer big picture view of productivity of employees and machines to improve processes. 


Real-Time Accurate Data

Having accurate real-time data can transform how you run your operations. From improved waste reporting, to improved machine efficiency, accurate production data brings real value, including labor and production costs, as well as the status of work orders in progress. If a client calls for an update, you will have the most up-to-date information at your fingertips.  


Faster Information Flow

How information flows through a business is a major factor in how efficiently it runs. An updated SFDC  ensures shop floor production processes are visible in real-time with intuitive reporting that gives you actionable insights into machine and employee efficiency, productivity, downtime, waste, estimated costs vs. actual costs, and more. 


Visibility Across Your Organization

Management is given unparalleled access to the most updated accurate information possible to make decisions and improve efficiency with data-driven adjustments. A fully integrated SFDC gives you visibility into machine speed, material usage, waste rates, machine downtime, and more – connecting your operations so you can respond faster, make smarter decisions, and keep your business on track.



With one comprehensive solution, Advantzware provides customers with a powerful tool to streamline data collection with touch sensitive monitors to take your business to the next level. A team of experts are on stand-by to help your business discover data and efficiency gains that you have been missing out on. Our dedicated team can show you how Advantzware’s intelligent shop floor data collection module integrates seamlessly into your ERP system and is built to increase the speed of adoption, reduce entry time and errors.

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Give us 30-minutes to show how we could help transform your company.

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Posted by jon in Shop Floor Data Collection