THE DIGITAL SOLUTION FOR THE PERMANENT MONITORING OF YOUR MATERIAL HANDLING PROCESSES
In many companies, machine monitoring is not yet based on facts, but rather on empirical values – an approach that is becoming increasingly unreliable as tasks become more complex and staff shortages increase. At the same time, smooth, safe, and cost-efficient operation must be ensured, even in economically challenging times.
This makes it all the more important to keep track of the condition of the machines at all times. This is exactly where the new i-STEP Operator comes in: an innovative tool that enables plant managers to monitor machines based on facts and helps them to make their daily work more efficient and forward-looking.
Real-time condition monitoring
The i-STEP Operator uses sensors from IFE and compatible third-party sensors to continuously collect relevant machine data. This data is automatically transferred to a user-friendly interface, where it is clearly structured and visually presented. This gives operations managers a comprehensive overview of the condition of their machines — without having to be on site in person. Monitoring can be carried out conveniently from the office or on the go via smartphone – anytime and anywhere. If deviations occur, the recorded telemetry data can be shared directly with the IFE specialist. This allows potential causes to be quickly identified and remedied in a targeted and proactive manner. This ensures minimal downtime and maximum efficiency.
Smart maintenance planning
When it comes to maintenance, with i-STEP Operator you don't have to rely on gut feelings and employee assessments, but can instead rely on solid data. A device-specific maintenance plan can be stored for IFE and third-party machines. Notifications and alarms immediately alert you to upcoming work, unplanned deviations, and thus possible malfunctions. This ensures a reduction in unexpected downtime, better scheduling of maintenance work, and higher operational reliability of the machine. Maintenance plans and alarms can also be customized.
Spare parts management
The i-STEP Operator is also the central hub for your IFE spare parts. By registering your IFE machine, the corresponding spare parts lists are automatically stored. Specific spare parts can be quickly identified and requested using dynamic full-text search. This saves valuable time when requesting spare parts.
Central access to documents
The document center provides further simplification. Original documents (e.g., operating instructions) can be accessed directly there. They are displayed on the platform in an integrated PDF viewer with a download function. Once the machine has been registered, all relevant documents are available regardless of location. This ensures that important documents can be found easily.
Data-based process optimization
The i-STEP Operator provides a reliable source for long-term machine assessment. Based on historical and reliable real-time data, machines can be analyzed over long periods of time. This enables specific condition assessments, makes trends transparent, and allows for data-driven predictive maintenance — a forward-looking maintenance plan. This means that work and repairs can be scheduled early on, avoiding unexpected downtime.
Integration of various sensors
Sensors from IFE as well as third-party suppliers (e.g., via OPC UA interface) can be integrated for machine monitoring. The IFE machine at IFAT 2024 was already equipped with i-STEP Vibrosense vibration sensors as well as sensors for pressure in the air suspension/air bellows, temperature, and current. i-STEP Vibrosense has open interfaces and can therefore be integrated into other systems via Modbus RTU or OPC UA.
On the i-STEP Operator platform, it is possible to create and evaluate virtual sensors, such as an operating hours counter, based on the sensors on the machine.
Sensors
for permanent condition monitoring
Thanks to various sensors, numerous factors can be monitored for reliable machine operation. Third-party sensors and machines can also be added to the Operator.
Operating hour meter
Air pressure sensor
Air pressure sensor
Vibrosense vibration sensor
Speed monitor
Speed monitor
Oil sensor
Oil sensor
Packages
Feature / Function | Light | Basic | Business | Enterprise |
| Basic Functions (Operating instructions, spare parts, IFE document management) | ✓ | ✓ | ✓ | ✓ |
| Online Data Transmission (Transfer and Display of Sensor Data) | x | ✓ | ✓ | ✓ |
| Machine Log (Maintenance, General Events) | x | ✓ | ✓ | ✓ |
| Alarms (Configurable Thresholds) | x | ✓ | ✓ | ✓ |
| Standard PDF Reporting (Alarms and Events) | x | ✓ | ✓ | ✓ |
| Dynamic Maintenance Planning (Based on Operating Hours) | x | x | ✓ | ✓ |
| Advanced Reporting (BETA) | x | x | ✓ | ✓ |
| Integration of Third-Party Sensors1 | x | x | ✓ | ✓ |
| Custom Developments for Enterprise2 | x | x | x | ✓ |
| Number of Sensors (per Machine) | x | 4+2 | 10+3 | 15+4 |
| Price per Month | free of charge | 290 € | 490 € | 890 € |
| Price per Year | free of charge | 3.306 € (-5%) | 5.586 € (-5%) | 10.146 € (-5%) |
1 Third-party sensors = Sensors not supplied by IFE. Possible IFE sensors include vibration (SES), oil quality and temperature, air pressure, and electrical power.
2 Billed according to actual effort
Adding machines and sensors
After logging in for the first time, you can register your own IFE machine using the serial number and machine type. Both details can be found on the nameplate.
Here, too, a comparison with the IFE customer database is carried out to ensure data security.
Sensors can be easily added by the user.
Users & roles
Users can now invite other employees to join the profile and assign roles with different rights.
- Manager
Full access, can invite other users, create machines and sensors - Worker
Has access to the data and dashboards and can also manage alarms and maintenance as well as log events.
IFE is happy to provide the necessary support during the setup phase so that you can quickly and fully utilize all the benefits.
The dashboard can be customized – similar to the home screen of a smartphone. Status indicators, charts, analyses, and other elements can be arranged and resized in the i-STEP Operator using drag & drop. This way, the most important information about your machine park is available at a glance.
Alarms and notifications can be customized. It is also possible to receive alarms and other messages via email so that no message is missed.
The timeline provides a compact overview of historical events and completed tasks, as well as a preview of upcoming maintenance, cleaning tasks, and much more. If a sensor reports a limit violation, this is also visible in the timeline. In addition to the standard entries that are automatically created when the IFE machine is registered, users can create their own maintenance entries, record events (e.g., unscheduled maintenance), and enter intervals for their own tasks (e.g., cleaning the screen linings every 100 hours). Notifications, e.g. for upcoming tasks, can also be created individually by the user. Entries can also be recorded or deleted retroactively in the timeline. The timeline and individual entries can be printed as an overview, with detailed information, or individually.
Base station
The i-STEP base station is a test kit containing four Vibrosense sensors, which are installed and configured at your premises by an IFE employee. This stand-alone solution allows you to test the full version of i-STEP Operator for an agreed trial period and see the benefits for yourself.
