Industry Conference On Industrial Maintenance

Cybersecurity is no longer an optional extra, but a prerequisite for a product to be placed on the EU market. Devices and software must be designed to minimize risk throughout the entire product lifecycle—from conception and development to withdrawal from the market.

The presentation will focus on the challenges faced by modern motion control systems in the context of growing demands for performance, cybersecurity, and scalability of solutions. It will discuss how integrated control architecture allows you to simultaneously implement advanced motion applications, meet the requirements of IEC 62443, and prepare machines for upcoming regulations such as the Cyber Resilience Act (CRA). The presentation will show how the new generation of motion systems enables high dynamics and precision while improving the energy efficiency of machines. Practical aspects of designing modern, safe, and scalable control systems for industrial applications will be presented.

We will present integrated drive and safety control based on the latest Sysmac automation platform. The following topics will be discussed: Integration of servo drives and AC drives (inverters) with Sysmac NX/NJ controllers via the EtherCAT network; Sysmac NJ/NX CPU as a motion controller; drive safety solutions using NX-Safety solutions on the Sysmac platform;  Sysmac Studio software simulation, monitoring, and recording of fast controlled axis waveforms, and verification of the correctness of the drive safety program.

The presentation will be devoted to reviewing the key achievements of successive Industrial Revolutions, with particular emphasis on the assumptions of the Industry 4.0 concept, especially in the context of the development of modern hydrostatic drives. The definition of hydrotronics, its origins, and the role it plays in modern drive technologies will be presented. An important part of the presentation will be a discussion of the directions of development of hydrostatic drives over the last fifteen years, in relation to the requirements and trends resulting from the Fourth Industrial Revolution. In addition, attention will be drawn to the issues of integrating control systems for various drive technologies — electric, pneumatic, and hydraulic — in modern machine drive and control systems, indicating their importance for the flexibility, efficiency, and intelligence of modern industrial systems.

During the lecture, we will show how modern hydraulic systems can significantly reduce energy consumption through the use of synchronous motors with energy recovery functions – both for the grid and for kinetic buffers. We will discuss intelligent energy consumption monitoring systems in technological processes and tools for monitoring machine operation, which enable continuous optimization of parameters and maximization of energy efficiency.

The presentation will discuss the challenge of monitoring the ‘health’ of electric drives, detecting anomalies and preventing potential failures, and will present a practical solution involving the use of ready-made, dedicated AI models for real-time prediction, characterised by low implementation costs.

Based on an actual line controlled by a PLC (Omron Sysmac Studio), I will demonstrate a methodical approach to: identifying and ‘proving’ the causes of sequence errors (e.g. premature axis movement resulting from transition/interlock/timing conditions), and reducing cycle time by analysing the step time of individual steps and selecting speed/acceleration/deceleration (V/A/D) parameters in relation to the critical path of the cycle, taking into account dependencies in the programme and safety/quality constraints.

IRIS is an AI-first Plant Operation System that integrates data, processes and people into a single factory operating system.

How does IRIS differ from classic MES / CMMS / BI?

AI is at the core of the system, not an add-on: 

o    it optimises operational decisions,

o    recommends actions,

o    analyses the effects of changes,

o    communicates with users in natural language.

One system instead of many tools: 

o    operations,

o    maintenance,o    efficiency,

o    management decisions.

IRIS ‘understands’ the factory - it not only reports data, but also suggests what to do next.

At the fair, we will show:

•    how AI communicates with users (operator, engineer, manager),

•    how IRIS supports maintenance decisions,

•    how specific operational recommendations are generated from data.

The proprietary DBR77 IoT system is a cheap, fast and independent implementation of production monitoring.

Key features:

•    Installation and commissioning in minutes, without stopping the line.

•    Can be implemented independently, without integrators.

•    Collects real data from machines and processes.

•    The ideal starting point for production digitalisation.

Business impact:

In many cases, the implementation pays for itself in as little as a week by eliminating waste, downtime and lack of visibility.

At the fair, we will show:

•    how to ‘revive’ a production line with data in a matter of minutes,

•    how IoT powers IRIS and Digital Twin,

•    real-life application scenarios in maintenance.

Consultifinity is a tool that:

1.    assesses a company's digital maturity level,

2.    sets out a plan for further development,

3.    automatically supports the implementation of this plan.

This is not a PDF report. It is an active system that guides the company through the transformation.

What makes Consultifinity stand out:

•    precise diagnosis (where the company really is),

•    a specific roadmap (what to do, in what order),

•    automation of the work of consultants and teams,

•    continuous monitoring of progress.

At the fair, we will show:

•    what a digital plant audit looks like,

•    how the system generates development initiatives on its own,

•    how AI monitors the implementation of the plan.

DBR77 creates complete digital twins of production plants, based on real data and stochastic simulations.

What are they used for?

•    designing new production plants,

•    rebuilding and optimising existing factories,

•    testing ‘what if’ scenarios without risk,

•    verifying investment decisions.

At the fair, we will show you:

•    how to design a new plant in Digital Twin,

•    how to check different layout, load and work organisation options,

•    how AI helps you choose the best option.

•    MES implementation in a production plant

→ 25% increase in efficiency

•    New plant design in a digital twin

→ layout and process optimisation even before construction

• Digital transformation of an automotive plant

→ organisation of data, processes and decisions

•    CMMS implementation at Apator

→ improvement of maintenance management

Each case study includes:

•    specific details, 

•    figures,

•    decisions,

•    conclusions.

DBR77 shows what an AI-managed factory looks like – from machine data and operational decisions to strategic transformation. 

You will not meet salespeople at our stand.

At the Maintenance Poland trade fair, DBR77 is represented by practitioners who work with production lines, maintenance and industrial plant transformation on a daily basis.

These are people who:

•    solve real problems on production floors,

•    implement MES, CMMS, IoT and Digital Twin systems,

•    design and optimise production plants,

•    work with operational data, not just presentations.

Discuss real implementations

Using specific examples, we will show you:

•    how we increased plant efficiency by 25% thanks to MES,

•    how we designed a new plant in a digital twin,

•    how the digital transformation of an automotive plant took place,

•    how CMMS was implemented at Apator.

No marketing. 

Just decisions, numbers and conclusions.

You can come with:

•    the problem of downtime,

•    chaos in maintenance,

•    lack of data from machines,

•    a plan to expand or rebuild your plant,

•    the question ‘where to start with digitalisation’.

And talk to people who solve such problems in practice – they don't sell licences, they look for sensible solutions.

We do not conduct a classic sales process at trade fairs.

We conduct engineering and operational conversations.

If:

•    the topic is simple → we will suggest a direction,

•    the topic is complex → we will show you how to approach it,

•    the topic is strategic → we will propose further cooperation after the fair.

At the DBR77 stand, you will meet practitioners, not salespeople.

We talk about real factory problems and real solutions — using examples from implementations.  

The presentation will focus on the critical stage of transition from traditional management methods to a digital CMMS system. We will concentrate on how the parameterization process—i.e., mapping the structure of the machine park, defining preventive plans, and building a knowledge base—determines the subsequent performance of the entire Maintenance department. 

We will focus on how to reduce response times and ensure that information about a failure reaches the right person in seconds!

Introduction of the Organizers and Overview of the Conference Theme

Examples of problems and challenges faced by maintenance departments and their root causes will be highlighted. Tools supporting modern maintenance will be presented. Good practices and case studies of companies that have implemented CMMS systems will be discussed, as well as examples of implementations that were not entirely successful, indicating the reasons for this and how to deal with it. The method of developing the system through modifications and integrations will also be indicated, and the aspect of change management during implementation will be discussed.

Digital twins (DTs) are virtual representations of physical assets, systems or processes, continuously updated based on operational data. In maintenance management, they enable predictive maintenance, real-time condition monitoring, data-driven decision-making and scenario simulation. As a result, DTs support increased maintenance efficiency, reduced downtime, improved safety and the development of new approaches to remote monitoring and training. In selected industries, they are already being implemented as an advanced evolution of simulation-based resource management. However, the effective use of digital twins in maintenance practice requires not only technological readiness, but also appropriate competencies and properly targeted engineering education. From a research perspective, current efforts focus on understanding how digital twins should be designed and used to maximise their impact on maintenance processes and engineering decision-making. The presentation addresses the role of universities in this transformation process, with particular emphasis on the integration of DT concepts into engineering education. The approach presented is based on the practical experience of the Warsaw University of Technology, Faculty of Mechanical Engineering, where digital twin-based solutions have been implemented as part of the ‘Maintenance Management’ course, combining scientific research, industrial tools and real-life operational challenges.

Maintenance is the heart of every factory, and digital transformation in this area is a business imperative. The presentation shows how process normalisation, system standardisation and simulation in a digital environment (using digital twins and XR (Extended Reality) technologies) enable the integration of robotics with PLC systems through SIMATIC Robot Integrator supported by Edge and AI applications integrated with SIMATIC Robot Library. Practical challenges and strategies for solving them will be discussed through Siemens' intelligent solutions combining robotic automation with data analytics and artificial intelligence, case studies from practice, and best practices ensuring effective implementation and increased competitiveness of factories.

The presentation will cover new methods currently used for data collection and processing in the broad field of maintenance. Examples of the application of these methods in industrial practice and the possibilities for their further development will be discussed. Digital technologies such as digital twins, digital product passports and blockchain, which are currently being incorporated into maintenance systems tailored to the applications and needs of the enterprise, will also be presented.

Siemens Sp. z o.o.

Communication chaos in a production plant affects many areas, including maintenance, production, health and safety, and quality. During my presentation, I will show how CMMS can serve as a common communication platform that organises processes and increases the efficiency of the entire plant.

During the conference, I will talk about vibration diagnostics projects implemented for our clients. I will present practical solutions and show how the implementation process actually looks like. I will also present the latest devices and applications that provide simple and clear information about anomalies in the operation of drive units.

We will show you the entire journey of a machine in the modern, digitalised world – from its design and production to its long-term operation and servicing, which can last for several decades. We will present the available digital tools and show you how to use them effectively at every stage of the product life cycle.

During the presentation, I will show how to move from individual tools and concepts to a coherent, functioning maintenance system in practice. I will focus on change management when implementing modern solutions – from CMMS and data analytics, through AI and predictive maintenance, to integration with automation and IT systems. The lecture will be based on experiences from real implementations in manufacturing plants and will show how to effectively combine technology, processes and people so that innovations actually improve the reliability and efficiency of the plant.