Preparing for FactoryWiz Monitoring
Preparing for FactoryWiz Monitoring
FactoryWiz Installation
This document is to help you understand the preparation which is required to ensure that your system deployment goes as smoothly as possible. We want to make sure that you have a good experience and that the project stays on schedule and on budget. With that in mind, please take the time to review this document with your IT professionals to make sure that there are no surprises, and everything is lined up for a smooth deployment.
Sample Installation Process
FactoryWiz will send a declaration of readiness (DOR) prior to the installation starting to ensure all required tasks have been completed by both parties.
Customer responsibility prior to installation
FactoryWiz onsite installation
Short Overview
- Blank server running MS Server 2016 / 2019 / 2022
- 8GB RAM
- 120GB HD Capacity
- 2 Core Processor
- .Net framework 2.0 / 3.5 / 4.0 / 4.5 / 4.8
- Domain service account for DNC service to login with on start (must have access to where the CNC programs are stored on the network).
- Ethernet connectivity to shop floor equipment
- Remote access for FactoryWiz engineer to configure the system or laptop with access.
- Clean install of MS server so we do not have conflicting software.
- Each machine has a terminated network cable in the machine.
- If we are connecting to the CNC, then the cable should be connected into the CNC
- If we are fitting an ADAM and or Moxa then the network cable will need feeding into the electrical cabinet.
- IP Addresses
- Each CNC, ADAM, Moxa we are using will require a static IP address. A list or range of addresses must be provided to the FactoryWiz engineer. The engineer will provide a job report stating which IP addresses are for what devices / machines. Please be aware that some machines will require 2 IP addresses if they have both ADAM and Moxa or Native connection and a Moxa.
- Machine Options
- Please ensure all machines have the required software options enabled (OPC-UA / MTConnect / Option 18 / etc)
- Wifi
- If using wireless tablets, then wifi will be required for then to connect to. This wifi must be able to communicate with the server.
- If possible, wifi access is required for the FactoryWiz engineer to use for connecting to the server.
- Remote Access (during installation)
- If possible, the FactoryWiz engineer will be able to remotely install and configure the new server using Microsoft RDP or equivalent. This is only required whilst onsite.
- SMTP Email
- FactoryWiz can send alerts and reports. SMTP account access is required for this functionality.
- Operator Engagement
- It is important to explain to operators and staff what FactoryWiz is and why it is being installed before the installation. We understand that machine monitoring, especially to operators, can seem like “big brother” looking over their shoulder. Often legitimate idle reasons are outside of the operators control and it is good for them to show this to management. Communication is key.
Post Installation Support
- Remote Support
- We typically use Zoho Assist. If you have a preferred remote access platform we are often happy to use that.
- Training
- Teams / GotoMeeting / Zoom / Zoho Meeting
- User guide and Tips n Tricks videos on FactoryWiz.com
- User manual on the desktop of the product
- Support Tickets
- Click on the support icon on the main menu of FactoryWiz to raise a support ticket. Or you can email support@factorywiz.com
Sample Factory Schematic
Firewall Rules
If you have the following machine types you will need to unblock the corresponding port on your firewall
Control | Protocol | Port | Direction |
Fanuc | TCP | 8193 | Server --> CNC |
| Siemens OPC-UA (any control with OPC-UA) | TCP | 4840 | Server --> CNC |
Mazak | UDP | 51001 | Server <-- CNC |
Heidenhain | TCP | 19000 | Server --> CNC |
Brother | TCP | 10000 and 20000 | Server --> CNC |
Okuma | TCP | 80 | Server <-- CNC |
MTConnect (Mitsubishi / Citizen) | TCP | 483 | Server --> CNC |
MTConnect (DMG Mori) | TCP | 7878 | Server --> CNC |
MTConnect (others) | TCP | Refer to vendor documentation | Refer to vendor documentation |
Haas NGC | TCP | 8000 and 8001 | Server --> CNC |
Modbus / ADAM Legacy | TCP | 502 | Server --> CNC |
Kitumura / HTTP | TCP | 80 | Server <-- CNC |
Moxa | TCP | 950-981 | Server --> CNC |
Legacy Machines
For machinery that doesn't have ethernet or communication protocols we use an ADAM 6051 signal monitor to determine the status (running / idle) or the machine. Where possible we will also collect DPRNT / FPRNT / SPRNT data from the RS232 serial port using a Moxa device.
If you are using both an ADAM and a Moxa, if you are not using an IA5xxx model of Moxa then you will need to run two network cables to the machine. The IA5xxx model acts as a bridge and RS232 device.
Tablets / Operator HMI
FactoryWiz use tablets / windows terminals to collect data from the operator, such as:
- Idle reason
- Reject reason
- Job information
- Operator name
We recommend either 10” Samsung Galaxy or 10” Apple iPad. These tablets have nonproprietary enclosures available. 10” gives the operator enough working area. The UI is viewed on any web browser.
In-depth Details
Server Readiness
FactoryWiz Monitoring is normally deployed as a virtual machine (VMware or Hyper-V are common but you may use the hypervisor of your choice), but may in some cases be configured manually on a physical server if a site does not have virtualization infrastructure in place. At this point in the process you should have already selected one of those options and indicated that to our FactoryWiz Application Team.
Virtual Server Deployment or Physical Server Deployment
In some cases, a customer may need to use a physical server. In those cases, you must pre-install a CLEAN copy of Windows Server 2012 R2, 2016, 2019, or the new unnumbered Windows Server. It is important that this server is not shared with other business software. Therefore, it is required that this is installed on its own server or virtual server. Typically, we will need to have an engineer spend a couple of hours online or onsite performing system configuration. It will be necessary for us to create a local administrative user for various running services and we will need to have administrative access to this local server account for the duration of the installation.
Network Considerations
Many customers segment their network into multiple VLANs. If this is of interest to you, there are a few things to consider. None of the machine tools need access to the internet, or to your network.
Machines communicate with the FactoryWiz server only. That server, likewise, is the only thing that tablets / operator entry screens or TV dashboards communicate with. The FactoryWiz server then aggregates all of that data and serves it up to any users through the web interface – so that server needs to be accessible from everything. If you decide to have your entire network on one segment – great. Easy enough. If you decide to split it into different VLANs, you may need to configure multiple virtual NICs on the server or you may prefer to set up limited routing between VLANs. This is all fine with us – as long as every device can communicate with the FactoryWiz Monitoring server, then you should be in good shape.
Machine Readiness
Each of your CNC or other equipment which is connected to FactoryWiz will need at least one static IP address. Some may need multiple addresses. If the deployment is wired, you may need a new network drop to the machine, or some machines will need multiple network drops. If you are connecting wireless, you won’t need a network drop but you will need an additional IP address for the wireless bridge we are installing on your machine. It can get very confusing keeping track of which machines need how many drops and addresses. For this reason, we have prepared a spreadsheet which indicates how many static IP addresses and drops you need for each machine. Please review this spreadsheet carefully and ensure that you will have these resources ready and completed before the start of installation. The number one reason installation costs go over budget is that cables are not run to the machines prior to start. Sometimes a machine may already have an Ethernet cable for file transfer so the customer skipped running one – that is a gamble because not all machines use the same Ethernet jack for monitoring data and file transfer.
3rd Party Integration / External Data Access
FactoryWiz is a fully open system. The system has 2 API's, a .Net DLL and a web based SOAP API or you can connect directly to the MySQL database. You can connect the system to ERP / MS Power BI / Excel / Etc. We can only advise how to use the FactoryWiz API and database, we do not have knowledge of all ERP systems.
Common Problems
“Cell” or “FMS” systems & cell controllers: FactoryWiz Monitoring can be deployed to machines even if they are controlled by a cell controller. FactoryWiz does not communicate with the controller – it communicates with the individual machines. On older machines where the cell is running via fiber link, we always run an Ethernet cable (or 2, etc. based on the spreadsheet) to the individual CNC. Where it gets complicated is when the cell is already communicating via Ethernet. We need to communicate (in most cases) with the same Ethernet line used by that cell. The best thing to do is to please call us and discuss your specific scenario. There are many different types of cells and machines and ways they could have been set up. It would be too confusing to delve into all the permutations in a document – but if you schedule a half hour call with us we can tell you the best way to connect your specific cell to your network.
Machines already having an Ethernet line: Some machines may already be connected to Ethernet in your shop for purposes of file transfer. The thing to be cautious about is the existing line may be plugged into an Ethernet jack other than the one which provides monitoring data. For example, many Fanuc controllers have both an Embedded Ethernet jack and a Board Ethernet jack inside the machine. You may only see one on the outside, but inside there is a cable that could run and plug into a board called a data server. The data server board will need to remain connected for you to load large programs into the machine’s extra hard drive (the data server) while having another run
to the embedded port with the FOCAS protocol we use to talk to the machine. Want to play it safe? Run the number of cables specified as though there were not already a cable to the machine. The cost tradeoff of pulling that additional cable when you already have a man on a lift is small compared to the cost to get someone back out there at a later date to run that cable plus possibly having to add costly days of engineer time onto the system installation.
Operator Tablet / Workstation Readiness
Because operator entry screens are just intranet pages, virtually any web enabled device can be used on the factory floor. Setting up each machine is simply a matter of pointing to the correct URL in a shortcut or home page setting. For example, http://192.168.1.100/mdi?CNC=Mazak1 might be the address for a data entry tablet on a machine called Mazak1. The specific URL may depend on any customizations to your tablet interface.
If you are using Android tablets we recommend downloading on each tablet and installing an app called “Kiosk Browser Lockdown”. This application will allow you to lock your device to the web browser and keep the screen turned on all the time when under power. Additionally, it will reconnect and refresh if the WIFI goes out for a few seconds and comes back.
Dashboard Readiness (large screen displays)
The TV dashboards are based on an actual program (EXE) running on a Windows 7 or above computer – they are not a web page. We have found this to be more reliable for extended use and gives us the ability to hide menus and taskbars. You should make sure that you have a Windows 7 or higher (Windows 10 Pro preferred) computer WITH NETWORK (Ethernet) port, attached to each TV via HDMI, DVI, or DisplayPort. Please do not use VGA – many TV’s limit the resolution to 1024x768 only through VGA. Your TV should be 1920x1080 resolution, also known as Full HD or “1080p” or alternately “4k” resolution (3840x2160). Do not get a 720p set, and do not use a monitor of a different ratio. The computer will probably default to 125% or 150% zoom on these displays – we turn that down to 100% so the display works with the boxes at the intended size (200% on a 4k set). While a normal program usually has some slack or scrolling, we have drawn these displays perfectly to the exact number of pixels to maximize screen space. Some customers use thin clients instead of PC’s – which can work, but sometimes configuring the resolution scaling setting to 100% is difficult on these and may require advanced knowledge. We don’t know about thin client settings so you’ll have to tackle that on your own if you go that route.
One last word – nobody has ever complained about the screen being too big, but very, very often we hear that a customer wishes they had gotten a bigger screen. We have seen 65” TVs on sale for as little as $600. We would absolutely recommend getting the largest set you are comfortable with – you appreciate it when you start adding additional pieces of information onto the dashboard in the future!
Engineer Access
Our engineer will be onsite configuring the system to work with your various machines. This engineer will need Remote Desktop access to the FactoryWiz Monitoring server for the entire duration of the installation. This could be with our engineer using his own laptop connected to your network or it could be using one of your workstations that you designate. Please have any login information available, including the server local administrative password, that the engineer will need.
Assistance
We want to help. If there is anything that is not clear it is best to get ahold of us and discuss it – the earlier the better. You can call (408)224-9167 and speak to the operator who will either be able to route you to someone that can answer your question immediately, or if it is more complex they will create a ticket to have a technician contact you. Please do not hesitate to take advantage of this service – it is in everyone’s best interest that this goes smoothly so we are happy to answer all of your questions.
Checklist and Scheduling
Now that you have a better idea of what preparations are necessary, we would like you to review that checklist in detail, make sure the server is prepped, cabling is arranged, addresses are documented, and schedule your installation. Please provide us with your desired dates (1st, 2nd, and 3rd choice) and we will schedule you at the soonest time available.
Appendix A: Common Product Questions
Q: What operating systems are supported?
A: We support FactoryWiz Monitoring on Windows Server 2016, 2019, or the new unnumbered “Windows Server” for your FactoryWiz Monitoring server. Because clients will be accessing the system via web browser, the client station OS is not generally an issue.
Q: Which web browsers are supported?
A: The intranet site supports all the major browsers (Edge, Chrome, Firefox, and Safari) for both mobile and desktop.
Q: Are Microsoft CAL’s (Client Access Licenses) required?
A: Microsoft states that a CAL is required for users / devices accessing intranet applications via IIS. FactoryWiz does not provide Windows Server licenses or CAL’s. It your responsibility to know which CAL count method (users / devices) is being used and to maintain the appropriate number. You may already have CAL’s which cover all of the users or devices which will access this new server. If your CAL level is at 2012 R2, you should make sure that you do not (as an example) choose to deploy FactoryWiz as a 2016 server without upgrading your CAL’s.
Q: Can I add this server to our active directory?
A: Yes – so long as we are also able to maintain a local administrative account for various services to run under, and no policy is pushed down which would make this account’s password expire.
Q: Can we add antivirus software to this server?
A: There are many different antivirus programs available so it is impossible for us to say with certainty if yours would cause any issue. The most common packages we run into in the field such as Symantec, AVG, Trend, and Sophos have been run successfully. One issue which does come up is that some of these packages may flag and remove our files and remove them after an update even though there is no threat – they are removed simply because Symantec has never seen them before. Because FactoryWiz monitoring files appear on a relatively small number of servers compared to something like an application that gets loaded on a desktop that flagging is likely to continue. It is best to exclude the “C:\RYM” and “C:\Program Files\RYM” folders from this type of flagging. Different vendors have different names for this type of flagging (SONAR is a name often used by Symantec). You may continue to have these folders scanned for known viruses, however.
Q: What server resources are required?
A: Disk requirements are minimal. 120gb allocated should be more than enough storage space. We recommend 8gb of RAM minimum with at least one processor core available. For systems over 30 machines we recommend 10gb RAM with at least two processor cores available, and for systems over 60 machines we recommend 12gb RAM with at least 2 processor cores available.
Q: Is there a database? What type? Can I access the data?
A: Yes – FactoryWiz uses Maria DB, which is already pre-configured when we distribute an image. It is not possible to use Maria DB or Oracle for the core functionality, although you can migrate between the two. All of the data is stored on-site in this database and you retain full access control over the database. Many customers use ODBC compliant software such as Microsoft Access, Microsoft Excel, or Crystal Reports to access FactoryWiz Monitoring data directly.
Q: Can we edit our reports?
A: Yes – all our reports are Crystal Reports templates. With a copy of Crystal Reports, you can edit existing reports or create entirely new reports to upload into the system. Once uploaded, reports may be viewed from any workstation or automatically emailed to designated recipients.
Q. How do we back up our FactoryWiz system?
A. FactoryWiz includes an automatic backup mechanism which can cleanly export all historic data, configurations, and licensing to a network location or USB drive on a nightly, weekly, or monthly basis. That export location may be included in your existing backup routine if desired. It is not necessary (or recommended) to attempt to back up the live MySQL server. Always backup the clean exported version instead.
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