Maximum availability through precise condition monitoring
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.
It's that easy
Registration & Self-Service
Registration is very simple: IFE customers can register on the i-STEP Operator Portal using their email address and VAT number. After verification with the IFE customer database, they will receive a confirmation email with their login details within a few working days.
After logging in for the first time, you can register your own IFE machine using the serial number. Here, too, a comparison with the IFE customer database is carried out to ensure data security. Sensors can also be easily created by the user.
The customer can now invite additional employees to the profile and assign roles with different rights. As a “manager,” you have full access, can invite additional users, and create machines and sensors. As an “administrator” within the organization, you have access to the data and dashboards. IFE is happy to provide the necessary support during the setup phase so that you can quickly and fully utilize all the benefits.
Dashboard & Alarms
Everything at a glance
The i-STEP Operator can be customized to suit your needs in many areas. For example, the dashboard can be designed as desired – similar to the home screen of a smartphone. Like “widgets” on a smartphone, diagrams, analyses, and various elements can be placed and resized in the i-STEP Operator using drag & drop. This allows you to see the most important information about your machine park at a glance.
Alarms and notifications can also be customized. It is also possible to receive them via email so that no messages are 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.
Always informed: the i-STEP Wiki
The i-STEP Wiki helps users find specific functions, better understand IFE's digital services, and stay informed about the latest developments. It contains quick guides, tutorials, screenshots, and news about i-STEP Operator. Like the platform itself, the Wiki is available in German and English.
On-site machine monitoring
The IFE Machine Monitoring Device integrates sensor data directly into your control system and enables predefined actions – from warning alerts to automatic shutdown. Depending on your needs, a complete control cabinet can be supplied, or the system with PLC can be installed directly into your existing setup.
And what happens next?
Starting in October 2025, i-STEP Operator will be available to all IFE machine operators. With the “Light” package, they will have free access to the portal, where they will be able to create machines and access related documents with limited functionality. Additional packages, including customized solutions, can be requested from your IFE contact at any time and offer further integration options for sensors, (third-party) machines, and an extended range of functions.
An i-STEP base station is now available as a test kit for interested parties. This includes four Vibrosense sensors, which are installed and configured in your own company together with an IFE employee. The stand-alone solution allows you to test the full version of the i-STEP Operator for an agreed trial period and see the benefits for yourself.
“With the i-STEP Operator, which was developed as a further refinement of i-STEP Workbench, we are delighted to now be taking the next step and providing our customers with a sophisticated tool that makes their day-to-day work noticeably easier, digitizes existing machines, and creates real added value,” summarizes Reinhard Hochstrasser, who is responsible for this product line in the after-sales department at IFE.
Anyone who is now curious can contact their IFE representative directly for further information and to request a personal demo.