DFC: DISA Foundry Cockpit

Pure foundry intelligence

A new platform for your data

The DISA Foundry Cockpit provides a flexible, scalable and central platform to access your foundry data, unlocking new possibilities and new insights from historical and real-time data.

By collecting data from the casting process into one system, deeper analysis and fast and effective trouble-shooting become possible. Ultimately, this enables foundries to increase equipment uptime, reduce scrap, minimise downtime, optimise production and improve casting quality.

Do more with your data

More and more foundry machines and devices are being developed to provide a wealth of data, in the spirit of the Internet of Things. 

The challenge is how to collate and make sense of this data in order to bring benefits to the smooth running of the foundry.

The DISA Foundry Cockpit offers a solution not just to the data collection and handling issue, it also creates the basis for doing more with your data to identify issues, intervene, learn and constantly improve. In short: it helps you turn foundry data into pure foundry intelligence.

Extensible, compatible, easy to use

The DISA Foundry Cockpit is accessed via an easy-to-use web-based interface that gives important process overviews as well as enabling detailed drill-downs into specific issues. It makes it easy to collect, correlate, analyse, monitor and exchange data.

Normalising unstructured data from various sources and turning it into structured data means better overall accessibility, but it also creates the foundation for seeing more in - and doing more with - your data.

Thanks to its modular design, the DISA Foundry Cockpit allows you to start small and add more equipment and data streams over time.

In tune, reliable and prepared

The importance of synchronisation

A key prerequisite for making data comparable and relatable is to have consistent timestamps across all data streams. Only then are you able to analyse for cause and effect across streams from different parts of the plant.

To achieve this, the DISA Foundry Cockpit provides a single central clock to which all parts of the system are connected. The result: reliable, synchronised data that gives you a true picture of when events coincided, preceded or followed one another. 

Prepared for what’s next

Moving from unstructured to reliably timestamped, structured data unlocks new possibilities to interrogate and engage with your data. It allows fast, plant-wide search, and gives quick access to historical data to compare against your real-time data. Most importantly, it creates the foundation for advanced data processing and analytics, helping you develop algorithms, find new connections, hidden insights and new ways of doing things better.

New tools for foundry data will emerge that can use this well-structured, accessible data. Some of these tools and algorithms you may develop in-house, many are currently in development at DISA, set to make your foundry even better. 

These new tools will dramatically expand what’s possible in terms of process control, efficiency and precision in foundry processes. The ultimate goal: perfect castings, no scrap, lean operations.

DISA Foundry Cockpit packages

The DISA Foundry Cockpit solution consists of several building blocks around a foundation package: DFC BASIC. Current packages available are: BASIC, CASTING and MOULDING.

The BASIC building blocks

Getting the BASICs right

DFC BASIC forms the heart of your foundry data solution. It provides the infrastructure needed to connect additional parts, but it is also rather powerful on its own. 

Click on the + icon to find out more. 

The user interface of the DISA Foundry Cockpit is as default available in English, German, Spanish and Chinese. Additional languages can be supported upon request.

Permissions, access rights and rules can be controlled by creating a personal user account for each user. There is no restriction on the amount of user log-ins.

The following features are all part of the DFC BASIC package.

Communication

Storage and processing of all data is carried out by an SQL database. The interface and data exchange between the moulding line and the database takes place via the onboard Ethernet port and is the basis for all encrypted communication. DISA Foundry Cockpit allows you to start small and add more equipment and data streams over time.

Pattern Recipes

A centrally controlled database to manage and store up to 30,000 pattern recipes helps improve uptime and reduce scrap rates. By storing the optimal pattern parameter set-up in the pattern database, production becomes independent of special knowledge carried by individual operators, minimizing the risk of mis-setting pattern parameters.

Document Cloud

The Document Cloud enables paperless access to all important machine documents. By accessing files via the local cloud storage, important documents won’t get lost and anyone with a DISA Foundry Cockpit log-in can share documents like service manuals, user instructions, pictures or maintenance procedures.

The following features require data collected by the MOULDING and/or CASTING packages.

Reporting

The DISA Foundry Cockpit offers several standard reports, including performance, production and casting reports. The report generator provides a flexible tool that allows the user to create, modify and customise reports. It also enables them to extract data from the system to share with others.

Dashboards

Dashboards offer a quick and easy way of viewing real-time and historical data. The dashboard feature also enables users to set individual preferences to show what’s important to them for easy monitoring and fast responses.

The MOULDING building blocks

Availability, performance, quality

The DISA Foundry Cockpit MOULDING package, provides a real-time overview of the performance of your moulding line.

Click on the + icon to find out more.

Uptime, productivity, and overall equipment effectiveness (OEE) are different ways of calculating and measuring performance.

Uptime is the time the machine is available and producing per shift. Productivity is expressed as the ratio of input to output for each pattern change, i.e. moulds produced vs moulds poured. 

OEE is the efficiency and utilisation of the equipment. Calculating and displaying these parameters is a preset feature of the DISA Foundry Cockpit. 

The state of your line 

Warnings, errors and events are continuously monitored and visualised to provide detailed information of the current state of the equipment. 

Historical data collection enables analyses and correlation of process data, alongside viewing in real time. 

Displaying the most frequent and most severe alarms along with equipment operations and sequences makes effective trouble-shooting possible.

Remote monitoring and supervision

Information from the operator’s panel of the DISA moulding machine (VDU) can be accessed remotely with DISA Foundry Cockpit, making it possible to monitor and supervise from a control room or your office desk.

The CASTING building blocks

Knowing your castings

The DISA Foundry Cockpit CASTING package gives a full graphical picture of the moulds on the cooling line. Each type of casting is visualised with distinct mould colours.

Click on the + icon to find out more. 

The mould colour changes to indicate new pattern plates on the line and each mould includes casting data for the specific mould produced and poured. 

A table view with all casting data is available and can be customised to show only the preferred data collection. Data can be added, removed, sorted and exported.

The recipes for success

Pattern parameters and pattern recipe data are available for each mould produced, meaning you can track parameter changes or compare recipes with actual performance. 

This data insight will enable you to optimise foundry processes and the performance of your line.

A solid foundation for your data journey

It’s just the beginning

With the DISA Foundry Cockpit, we have developed a solid foundation for your data journey. We’ve created it, because we believe that data and digital technology offer great opportunities for our industry and are the key to its continued success.

More innovation will follow built on this strong basis. The DISA Foundry Cockpit will allow you and your foundry to make a big leap forward right now.

Investing in digital technology

DISA is committed to supporting your digital journey and maximising the value of your data to keep you competitive and profitable.

At the heart of our digital developments are a deep knowledge and understanding of the foundry process, ensuring our solutions are not gimmicks, but solve your challenges and improve your castings.

The key that starts the journey

The DISA Foundry Cockpit is sold in software packages in combination with a licence fee. There are licence keys and associated fees for the different data and functionality packages.

Availability

The DISA Foundry Cockpit is currently available as an option for all new DISAMATIC® D3 moulding lines.

Enquire about the DISA Foundry Cockpit today

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