BDE (Production Data Collection) explained simply
Imagine your production as a beating heart: every machine, every shift, every step provides information. BDE captures all this data – machine run times, quantities, error messages, working hours – and makes them visible. This gives you clarity about the actual production status – and you do not act on gut feeling, but on the basis of real facts.
Background information
BDE refers to the systematic process of recording and processing actual data in the production environment – including technical data (machine run times, faults, material consumption) as well as organisational data (working hours, order status). Modern BDE systems combine hardware (terminals, sensors, barcode/RFID readers) with BDE software to record, process and transmit data – automatically or manually – to higher-level systems such as MESManufacturing Execution System - software for real-time control and monitoring of entire production., ERPEnterprise Resource Planning - software for integrated management of all business processes and resources. or SCADASupervisory Control and Data Acquisition - system for centralized monitoring and control of technical facilities with real-time data acquisition..
These systems increase transparency, improve production planning, enable target-actual comparisons and create the foundation for data-driven process optimisation.
Technical architecture and components of a BDE system
A typical BDE system is structured hierarchically and comprises the following components:
- BDE-machine terminals: Mounted directly on the machine or in the control cabinet, these record data such as run times, faults or order feedback.
- BDE-area terminals: Collect data from several machines or workstations in a production area.
- BDE-group computers and BDE-concentrators (interfaces): Aggregate the collected data and forward them in bundles to the control computer.
- BDE-control computer: Central data hub which stores, processes and forwards data to systems such as MES, ERP or SCADA.
- Hardware & software: BDE includes both sensors and terminals as well as software for data capture, analysis and visualisation. Integration with MES or ERP is key to overall benefit.
This structure enables reliable, scalable capture and utilisation of production data – from the shop floor to management.
Key figures & evaluation – use of BDE data for production control
The BDE data collected forms the basis for calculating key production performance indicators (KPIs):
- OEEOverall Equipment Effectiveness - key performance indicator for measuring overall equipment efficiency from availability, performance and quality. (Overall Equipment Effectiveness): Determines effectiveness through availability, performance and quality – crucial for assessing equipment productivity.
- Machine utilisation and availability, fault detection, throughput times, scrap and rework rates are typical control variables directly calculated from BDE information.
With these indicators, bottlenecks can be identified, processes optimised, energy and materials managed in a targeted manner, and ultimately production performance can be significantly increased. Dashboards and visualisations make this data not only accessible but also usable – whether in the control room or on the move with the shift supervisor.
Further information and links
- mind-logistik.de: BDE in Industry 4.0Fourth industrial revolution through digitalization and intelligent networking of production facilities. – automation, data use, transparency
https://mind-logistik.de/knowhow/betriebsdatenerfassung/ - symestic.com: What is a BDE system? – real-time function, automation, distinction from MES/MDE
https://www.symestic.com/de-de/blog/betriebsdatenerfassung-bde - iSAX Blog: Advantages & benefits of BDE – data use for planning, control, transparency
https://www.isax.com/unternehmen/blog/betriebsdatenerfassung-bde/ - MPDV Smart FactoryIntelligent factory with fully networked machines and systems that self-organize and produce autonomously. Glossary: BDE & MES – data basis for production optimisation, classification within the system network
https://www.mpdv.com/industrie-4-0/smart-factory-glossar/betriebsdatenerfassung-bde