PlasserDatamatic 2.0 – controlling operation and maintenance digitally

Right on time for InnoTrans 2018, Plasser & Theurer will relaunch PlasserDatamatic, revolutionising machine operation and maintenance. Our customers will benefit from entirely new opportunities allowing them to increase the availability of the machines and improve the efficiency of machine maintenance.

In the future, the standard equipment of Plasser & Theurer machines will include the new PlasserDatamatic 2.0. The web-based system is user-friendly and can be configured individually. Access to the internet is all the operator needs to connect to the machines – no matter how far the distance. The system benefits all members of staff involved in the operation and maintenance of the machine: The management receives informative reports, providing the basis for strategic decisions. Fleet and maintenance managers can access information on the condition of the machines at any time, allowing for condition-based maintenance and enabling them to plan required measures ahead of time. Machine operators can carry out all maintenance operations safely and transparently via a smartphone app. 

PlasserDatamatic 2.0 is designed as an expandable platform. Currently, it is composed of two subsystems: The MachineConditionObserver (MCO) supplies relevant data on the machine status. Using the data, it regularly prepares reports. The MachineMaintenanceGuide (MMG) is a digital service booklet, taking the efficiency in machine maintenance to a whole new level.   

All in view from the office 

PlasserDatamatic 2.0 connects the machine and the operator’s administration and supplies data on the machine’s condition online in an individual configuration. At a glance, it provides all important geographic data on the current operation, all data on the machine, the entire machine documentation in the latest version and latest error messages. This is how the system provides an optimum overview of the machine condition in real time. It goes without saying that the data may only be accessed by authorised persons. When developing the system, the EU’s General Data Protection Regulation was taken into account. 

Individual reports at regular intervals

In addition to the data on the machine’s condition, the MCO generates regular reports based on the enormous amounts of data that are collected permanently. The reports are sent to the operator’s office by email on a daily, weekly, monthly and annual basis. They enable the management to take strategic decisions on the basis of computer-generated information. Reports on individual machines can also be used to improve the operation and maintenance of the entire fleet.

Regularly updated error messages compiled in top ten lists are another innovation. They make it possible to become aware of problems before they cause downtimes. Should an incident occur, its causes can be localised and remedied more easily. Following repair, PlasserDatamatic 2.0 is an important and objective feature to check the effectiveness of the measures taken.

PlasserDatamatic 2.0 supplies data on the machine’s condition online in an individual configuration.

Step by step to efficient optimisation

The digital service booklet MMG (MachineMaintenanceGuide) is the second subsystem of PlasserDatamatic 2.0. It enables machine operators to document maintenance operations immediately using their smartphones. Following a simple step by step procedure, check points are answered with yes or no or conditions are assessed.

Upon completion of the maintenance pass, the machine operator signs the document. Then, the fleet manager can access the maintenance status right away. For the first time, Plasser & Theurer’s MMG allows a transparent and constructive dialogue between machine operators and fleet managers. It supplies the operator’s service staff with all the required information to order spare parts on time and to plan maintenance work and repairs ahead of time. This provides the optimal preconditions for a condition-based maintenance strategy. It allows making full use of the cost-efficiency benefits of predictive maintenance.

Operated in the USA and Japan

Since May 2018, PlasserDatamatic 2.0 has been used on BNSF machines in the USA and on machines in Japan. The experiences gained so far have been more than promising: Within a short time, PlasserDatamatic 2.0 has become an indispensable tool for planning and implementing measures for the operation and maintenance of tamping machines. 

As of early 2019, the standard equipment for new Plasser & Theurer tamping machines all over the world, and all new machines for the European market, will include the new system. In a next step, the system will also be available as an upgrade for machines that have already been put into operation.