Optical Performance Logger – OPL3.0

Development of an automated tool for analyzing the efficiency of production plants

It is becoming increasingly important to measure the efficiency of production plants because of the ever rising energy and raw material costs. In addition to internal production data acquisition systems, external observations by trained personnel, in particular for determining machine-related parameters as laid down in DIN 8743:2014, are also a key aspect of these analyses.

The Fraunhofer IVV Dresden has performed efficiency analyses on working production plants since 1995. The research project described here developed an innovative tool to further expand the analytical capabilities. Accurate efficiency analysis was made possible by automated measurement of output rates, product quality, rejects, energy consumption, and throughput in combination manual evaluation of the causes of faults.

This allows technical and organizational optimization of production processes at companies and also provides the basis for the development of innovative assistance systems.

The total system comprises central server-based data acquisition software and various autarkic subsystems (satellites). The satellites transfer data to the server via a wireless network. This allows the acquisition of parameters at several locations in the production plant. All data are stored in a central database and can be viewed and edited on computers at the central monitoring point or using other devices (tablets and smartphones). Faults can be observed and documented directly at the actual locations where they occur, even by several people simultaneously. The data provide a solid basis for the preparation of detailed reports.

Project term: 2015 to 2016
Project management
/project funding:
Sächsische Aufbaubank
/State of Saxony