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KOMTRAX

Instruction Manual

(For North America and Southeast Asia, the 1st edition)

Issued on January 31, 2015

Komatsu Industries Corp.

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■Contents
1.1. Formation of KOMTRAX ........................................................................................................ 3
1.2. Necessary device and environment ........................................................................................ 4
1.3. Exemption clauses ................................................................................................................... 4
2. Basic Instructions ........................................................................................................................... 5
2.1. Internet connection.................................................................................................................. 5
2.2. Login ......................................................................................................................................... 5
2.3. Logout ....................................................................................................................................... 5
3. Explanation of Screen and Operation ........................................................................................... 6
3.1. Explanation of screen .............................................................................................................. 6
4. Definition of Time and Times on display ...................................................................................... 7
5. Current Production ......................................................................................................................... 8
6. Production History ........................................................................................................................ 10
7. Machine Library............................................................................................................................ 11
8. Machine Running Status .............................................................................................................. 12
9. Specified Period Running Status ................................................................................................. 13
10. Daily Report 1 (report output: part number control, list type) .............................................. 14
11. Daily Report 2 (report output: part number control, band graph type) ................................ 15
12. Maintenance Inspection Information ...................................................................................... 16
13. Event History............................................................................................................................. 18
14. Modify Machine Information .................................................................................................... 19
15. Other Functions......................................................................................................................... 20
15.1. Search Criteria ................................................................................................................... 20
15.2. Sort ...................................................................................................................................... 20
15.3. CSV Download.................................................................................................................... 20
15.4. Modify user information .................................................................................................... 21
15.5. Change Password ............................................................................................................... 21
16. Operator Administration .......................................................................................................... 22
17. Contents Added with Upgraded Software Version for Machine ............................................ 23
17.1. Current Production ............................................................................................................ 23
17.2. Machine Running Status ................................................................................................... 24
17.3. Specified Period Running Status ...................................................................................... 26
17.4. Daily Report 1 (report output: part number control, list type)....................................... 27
17.5. Daily Report 2 (report output: part number control, band graph type)......................... 29

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Introduction
The KOMTRAX is a system that operation status of the machine is automatically collected
and can be seen and controlled through Internet.

1.1. Formation of KOMTRAX


The KOMTRAX System consists as shown below:
(1) The KOMTRAX terminal continuously watches and measures conditions of the machine
on which it is incorporated.
(2) The measured data are sent out to the KOMTRAX Server (at Komatsu Computer Center)
via portable and wireless transmission channel every one hour.
(3) The data are accumulated and aggregated on the KOMTRAX Server.
(4) Operation conditions of the machine can be taken out in the form of tables and graphs
through the Internet.

Portable and wireless


transmission KOMATSU

External
antenna KOMTRAX
Client's machine
Server

Control panel
Internet

KOMTRAX
Terminal

Client's PC

Client's company

* The PC for WEB browsing and Internet environment have to be prepared by the clients.

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1.2. Necessary device and environment
■ PC for Internet connection
It is recommended to browse with the resolution of 1024 × 768 (XGA) or higher.
■ Internet connection channel
Internet Explorer (Version 7.0 or later is recommended.)
Google Chrome (Version 39.0.2171.71 or later is recommended.)
■ Software for PDF files (Adobe Reader etc.)
The Adobe Reader can be downloaded free from the below link.
http://adobe-reader.joydownload.net/

Above articles are requested to prepare by the client.

1.3. Exemption clauses


Following items are out of our obligation with this system:
(1) We do not guarantee accuracy of the information provided by us.
(2) The system may be interrupted for maintenance without prior notice.
(3) Obtaining information may be impossible or unstable depending on the location of the
machine since the portable and wireless transmission channel is used.
(4) The KOMTRAX WEB screens and software shall be subject to change without prior notice
for improvement.
(5) The contents of this manual shall be subject to change without prior notice. No part of this
manual shall be reproduced.

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2. Basic Instructions
2.1. Internet connection
connection
Start the WEB browser and enter the below URL to the address bar.
https://snk-komtrax.komatsu.co.jp/komtrax.KMTR.WEB/
(Enter all letters starting with https://...)

2.2. Login
By connecting to the address above, the scree as shown below shall be displayed.
Enter user ID and password, and press the "System Starts" button.
(Note that upper-and lowercase letters of user ID and password have to be distinguished.)

Remarks:
The user ID and initial password shall
be written on a separate sheet. If you
have lost, contact the "Address for
inquiry" described in the section
above.

By checking the [Record User name and Environment.], entering the user ID and password
can be omitted from the next time.
Use [Language] and [Date format] as they are.

2.3. Logout
The logout screen shall appear by clicking the [Exit] link on the left of any screen. And you shall
be automatically logged out if you don't operate for 30 minutes.
(* You are not logged out automatically on some screens because of automatic screen
refreshment.)

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3. Explanation of Screen and Operation
3.1. Explanation of screen
The typical KOMTRAX screen is divided into the following three areas.

② Search Criteria area

③Shortcut ①Information Display area


Menu area

① Information Display area (bottom right of the screen)


Information on various machine statuses shall display. Contents are different depending on
each screen. See explanation of each screen for details.
② Search Criteria area (top right of the screen)
When too much information is displayed in the Information Display area to find objective
information, it can be limited by using here. See "Retrieval of Information" for using this area.
(No Search Criteria area is provided on some screens.)
③ Shortcut Menu area
area (left of the screen)
Links to an objective screen are located.
Three categories of [Machine Overview], [Machine Monitoring] and [User Administration]
are provided in addition to [Exit].
[Machine Overview]: function of displaying information of all belonging machines. Click
"Machine Library" for moving to the machine list screen.
[Machine Monitoring]: function of displaying information of a particular machine. Enter
Machine Model and Serial Number (omissible) and click the link for the screen you
want to see.
[User Administration]:
Administration]: Your password can be changed here.
[Exit]:
[Exit]: to terminate KOMTRAX to move to the Logout screen.

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4. Definition of Time and Times on display
■ Display of time or duration
Power-on Duration: hours during which the control power of the machine is turned ON.
Operation Time: hours during which the machine is operating
Production Duration: hours during which the machine is operating in the production mode.
Idle Time: hours during which the machine is not operating in the production mode.
Set-up Duration: hours during which power is turned ON but not for production (hours during
which the machine is either operating or stopping with power-on but not in the
production mode)

Summed Power-on Hours: total of power-on hours since KOMTRAX was installed
Summed Operation Hours: total of operation hours since KOMTRAX was installed

■ Display of Times
Operation Times
Type of machine Description
PRESS MACHINE Number of stroking
PRESS BRAKE Number of pressurizing
TWISTER,
LEASER PROCESSING MACHINE and Number of piercing
FIBER LASER PROCESSING MACHINE
GATLING PRESS CENTER Number of punching

Number of Production Times: number of operation times with selecting the production mode

Summed Operation Times: total of operation times since KOMTRAX was installed
Summed Production Times: total of production times since KOMTRAX was installed

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5. Current Production
Operation statuses and abnormalities of all the machines in the plant are integrated and
displayed. The display can work as an operation bulletin to grasp current status of the machines
in the plant (as below).

■Description of displayed information


Inspection: Information only of the machine(s) checked here is displayed.
<How to use>
① Click to check the box on the left column of the list.
② Click to check the box for "Display machines with check only" in the Search
Criteria area.
③ Press the "Search" button.
* Abnormal: Indication turns ON if an abnormality arises with the machine.
Alarm: red indication; Caution: yellow indication
Maintenance: Indication turns on if parts replacement is required with the machine.
Replace now: red indication; Replace soon: yellow indication
Installation Site: Enter location of the machine. (Any description to your convenience is
allowed.)
Machine Name: machine number, line name etc. (any description to your convenience)
* Order No.: Upgrading your production machine is required to display.
* Product Identification No. Name: Upgrading your production machine is required to display.
* Operator: Upgrading your production machine is required to display.
Running Status: Blue bands are displayed with production hours.
Running Rate: percentage of "production hours" out of power-on hours
Production Duration: hours when the machine produces

* Real-time display: Screens are updated every 5 minutes.

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Production Count
Type of machine Description
PRESS MACHINE Number of stroking
PRESS BRAKE Number of pressurizing
TWISTER
LEASER PROCESSING MACHINE Number of piercing ON
FIBER LASER PROCESSING MACHINE
GATLING PRESS CENTER Number of punching
* With selecting the production mode

Power-on Duration: Hours during which the control power of the machine is turned ON.
Software Version: Software version of KOMTRAX terminal shall be displayed.
Country: Country where the machine is operating shall be displayed.

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6. Production History
The history of the operation bulletin can be displayed by selecting the date (as shown below).

■ Description of displayed information


information
Inspection: Information only of the machine(s) checked here is displayed.
<How to use>
① Put a check by clicking the check box on the left column of the list.
② Check the box for "Display machines with check only" in the Search Criteria
area.
③ Press the "Search" button.
Installation Site: Enter location of the machine. (any description to your convenience)
Machine Name: Serial number, line name etc. (any description to your convenience)
Running Status: Blue bands are displayed with production hours.
Running Rate: percentage of "production hours" out of power-on hours
Production Duration: hours when the machine produces
Production Count:
Type of machine Description
PRESS MACHINE Number of stroking
PRESS BRAKE Number of pressurizing
TWISTER
LEASER PROCESSING MACHINE Number of piercing ON
FIBER LASER PROCESSING MACHINE
GATLING PRESS CENTER Number of punching

* with selecting the production mode


Power-on Duration: hours during which the control power of the machine is turned ON
Software Version: Software version of KOMTRAX terminal shall be displayed.
Country: Country where the machine is operating shall be displayed.

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7. Machine Library
The list of your machines that comply with the KOMTRAX is displayed (as shown below).

Check: Information only of the machine(s) checked here is displayed.

Check: Information only of the machine(s) checked here is displayed.


<How to use>
① Put a check by clicking the check box on the left column of the list.
② Click to check the box for "Display machines with check only" in the Search
Criteria area.
③ Press the "Search" button.
* Abnormal: Indication turns on if an abnormality arises with the machine.
Alarm: red indication; Caution: yellow indication
Maintenance: Indication turns on if parts replacement is required with the machine.
Replace now: red indication; Replace soon: yellow indication
Machine Type: name of major grouping of the machine (press, laser etc.)
Machine Model; Model Type: brand and model of the machine
Serial Number: of the machine
Installation Site: location of the machine (any description to your convenience)
Machine Name: machine number, line name etc. (any description to your convenience)
Cumulative Production Duration: total of operation hours since KOMTRAX was installed
Cumulative Production Count: total of operation times since KOMTRAX was installed
Last Communication Time: last time when the machine communicated with the Server
Production Date: of the machine
Maker: name of the machine manufacturer
Country: country where the machine is located
* Real-time display: screen updated every 5 minutes

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8. Machine Running Status
Operation status of a specified date for a specified machine can be seen (as shown below).
Since initial display information will be of the day, enter the date and time you want to check into
the "Appoint Period" columns.

Graph ① Numerical value ①

Numerical value ②

Graph ②

■ Description of displayed information


Graph ①: Band graph
Power-on: Green bands show the duration of power-on time.
Production: Blue bands show the duration of production time. (Status that machine is
operating with control power ON and production mode ON)
Abnormal: Red bands show duration of abnormal time.

Graph ②: bar graph and line graph


SPM (strokes/min) (blue column graph): production times per one minute; average of
production counts for 6 minutes
Production Count for the Day (red line graph): total production times of the day

Numerical value ①: percentage of each hours out of power-on hours

Numerical value ②: operation rate and total production count


Running Rate of the Day: percentage of "production hours" out of power-on hours
Production Count for the Day: total production times during appointed period

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9. Specified Period Running Status
Operation status in a specified period is displayed in the unit of day. You can know production
status of every day.

①Collection period and display time

② ③ ④ ⑤ ⑥

⑦ ⑧ ⑨ ⑩ ⑪

■ Description of displayed information


① Period Appointment: Appoint collection period and display time.
② Number of Days of Period: Number of days in the collection period is displayed.
③ Number of Days of Operation: Number of days when the power (to the KOMTRAX) was
turned ON in the collection period is displayed.
④ Production Duration; ⑤ Production Count; ⑥ Power-on Duration
Average calculation: Total value during the operation days is divided by the operation
days.
Total calculation: Total hours or times during the operation days are displayed.
⑦ Date: of the collected days. Days of no power-on are not displayed.
⑧ Running Status: Operation status of each day is displayed in one minute unit. Minutes
when the machine is running are displayed in blue. Abnormal minutes are in red.
⑨ Running Rate: against specified hours of the day
⑩ Production Duration; ⑪ Production Times; ⑫ Power-on Duration: Totals of specified
hours and production times during the collected days

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10. Daily Report 1 (report output:
output: part number control,
control, list type)
type)
Operation status of the appointed machine is output in a report form. A feature is that
memorandums on the job can be input directly from the PC. The output can be stored as a PDF
file, or be printed out (A4 size is recommended).

① ② ③ ⑦ ⑧

■ Description of displayed information


① Period Appointment: Enter dates for output.
② Time Appointment: Enter start time and end time for the graph output. (It will be
convenient to enter start time and end time of your working hour.)
③ Update: of the screen
④ Company Name, Department and Name: Enter person in charge for the report. (Omissible)
⑤ Operation Contents: Enter comments per every one hour. (Omissible)
⑥ Remarks: are displayed in the comment column on the bottom of the report. (Omissible)
⑦ PDF Output: Click for displaying the PDF output screen.
⑧ Data Updating: Click for updating the operation data.
* Previous contents for ② Time Appointment and ④ Company Name, Department and Name
are displayed as initial values next time.

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11. Daily Report 2 (report output: part number control, band graph type)
Operation status of the appointed machine is output as a report form. The output can be stored as
a PDF file, or be printed out (A4 size is recommended).

① ② ③
⑪ ⑫

⑥ ⑦


■ Description of displayed information


① Period Appointment: Enter dates for output.
② Time Appointment: Enter start time and end time for the graph output. (It will be
convenient to enter start time and end time for the work.)
③ Update: of the screen
④ Company Name, Department and Name: Enter person in charge for the report. (Omissible)
⑤ Bar graph for number of production times: production times per one minute; average of for
6 minutes
⑥ Line graph for total production count: cumulative production count for the day
⑦ Operation rate of the day: percentage of "production hours" out of power-on hours
⑧ Sum of operation count of the day: aggregate production count during appointed period
⑨ Band graph of operation: Power-on hours, production hours and abnormal time are
displayed.
⑩ Remarks: are displayed in the comment column on the bottom of the report. (Omissible)
⑪ PDF Output: Click for displaying the PDF output screen.
⑫ Date Updating: Click for updating the operation data.
* Previous contents for ② Time Appointment and ④ Company Name, Department and Name
are displayed as initial values next time.

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12. Maintenance Inspection Information
This is the screen for maintenance (inspection and replacement) of your machines. You can
control the next maintenance on hours and times considering the previous date.
Press the corresponding "reset" button after maintenance.


① ② ③ ④ ⑤ ⑥ ⑦

■ Description of displayed information


① Maintenance Items: check points on the machine
② Specify Interval: recommended maintenance intervals
③ Current Value: elapsed hours till now
④ Last Maintenance Date: previous date of pressing the reset button
⑤ Remaining Interval: hours or times before the next maintenance
⑥ Reset: Press this button after maintenance.
⑦ History: for displaying resetting history

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⑧ Reset Time: Enter the date of maintenance. The maintenance information is processed
based on this date.
⑨ User Original Maintenance Item: Items you want to check and control can be added and
changed. You can handle them the same as other maintenance items.
⑩ Machine and Company Information: Location, Company, Person in charge, Telephone
Number, Fax Number and E-mail for the machine are displayed. The location is
linked with the Google map.
Note) Figures in items ②, ③ and ⑤ above with the unit "H" are "residual intervals in hours
and with "times" are "residual intervals in times."

Note) See the maintenance manual of individual machine for concrete maintenance
contents for each item.

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13. Event History
Occurred and occurring alarms, warnings and interruptions are displayed.

① ② ③ ④ ⑤

By appointing the collection period and pressing the "Update" button, the alarms and errors in
the period are displayed as a list.

■ Description of displayed information


① Code: See each machine manual for concrete contents.
② Sort: "Warning " or "Alarm" is displayed.
③ Text: The message made with the alarm or error is displayed.
④ Time of Occurrence: The date and time when the error occurred are displayed.
⑤ Times of Occurrence during the Period: Number of the same errors occurred in the
collection period is displayed.
⑥ Machine and Company Information: Location, Company, Person in charge, Telephone
Number, Fax Number and E-mail for the machine are displayed. (These items are
registered on the "Modify Machine Information" screen.) The location is linked with
the Google map.

Note)
Obtaining and displaying the Error Code are not possible with some machines.

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14. Modify Machine Information
The name and information of the machine can be set. Use here for your convenience.






■ Modify Machine Information


Enter information and press the "Modify" button.
① Installation Site: Enter location and section of the machine. (Plant name, line name,
section name etc.)
② Machine Name: Enter a common name of the equipment. (Line number, product name etc.)
③ Representative: Enter person in charge for the machine.
④ Telephone Number: of the person in charge
⑤ Fax Number: of the person in charge
⑥ Email: of the person in charge

■ Modify Period/Times of Replacement Date (offset setting)


Replacing intervals of the maintenance parts can be modified. Use here for your convenience.
Enter offset values and press the "Modify" button.

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15. Other Functions
15.1. Search Criteria
Information to display can be limited by entering letters to narrow down into the "Search
Criteria" columns and pressing the "Search" button. Only the information to comply with the
entered letters is displayed.

Search Criteria
・Machine Sort and Maker: Select from the pull-down menu.
・Installation Site and Machine Name: Enter a key word in the text box. (partial-match
search)
・Machine Model, Model Type and Serial Number: Enter a key word in the text box.
(complete-match search)
* Wild card (*) search is also possible.

15.2. Sort
By clicking the item description, the list is sorted in ascending order with the column of the
item. The list order changes in the order of (ascending → descending → no sorting →
ascending) on each clicking.

15.3. CSV Download


On the screen where [CSV Download] button is provided, the equivalent data with the
displayed data can be downloaded as a CSV text file. Since the dialog box for saving the file shall
be displayed by pressing the [CSV Download] button, save it at your appropriate location.
The saved file can be used with miscellaneous spreadsheet and database programs. (See the
manual of the software for using the file.)

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15.4. Modify user information
Your contact address and daily report in one-screen display can be changed.

If your telephone and fax numbers are changed, please modify them since we use them for
communications with you.

15.5. Change Password


You can change your password.



① Current Password: Input your password before modification.


② New Password: Enter your new password.
③ Confirm Password: Enter the same New Password again.
The password has to be in 6 through 20 characters. Note that upper-and lowercase letters are
distinguished. Changing your password periodically is recommended.

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16. Operator Administration
This is the setting screen for combining the "operator code" on the machine with the name
displayed on the WEB. The name is displayed as the operator name on the daily reports.

Note)
Registration and modification are possible, but deletion is not possible.

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17. Contents Added with Upgraded Software Version for Machine
17.1. Current Production

Data ① Graph ①

Graph ①

Data ①: Order No., Part No. and Operator have been added.
* Order No.: Currently producing Order No. with the machine is displayed.
* Product Identification No. and Name: Currently producing Part No. with the machine is
displayed.
* Operator: Currently working operator with the machine is displayed.

Graph ①: Running statuses are expressed in different colors.


Running Rate: Percentages of "Production” hours, "Idle” hours and "Set-up” hours out of
“Power-on” hours are graphically displayed.
Production hours: blue; Idle hours: yellow; Set-up hours: orange

* Real-time display: * Real-time display: screen updated every 5 minutes

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17.2. Machine Running Status

Graph ①

Graph ②

New feature

Table ①

Table ②

Table ①: Production control table per each part number has been added.
It will support your production control by contrasting the production plans with the
production results.
・PRESS MACHINE and PRESS BRAKE

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・TWISTER, GATLING PRESS CENTER and LEASER PROCESSING MACHINE

New feature
・FIBER LASER PROCESSING MACHINE

Table ②: Consumables control table has been added.


・TWISTER
By displaying the utilization rates on replacing, wrong usage can be avoided. And such
machine troubles as an abnormal torch can be judged.

Graph ①: Band graph for idle and set-up hours has been added.
By adding the idle hours and set-up hours, more details of production status can be seen.
Idle: Idle hours are displayed in yellow. (Status that machine is not producing with control
power ON and production mode ON)
Set-up: Set-up hours are displayed in orange. (Status that machine is operating with control
power ON and production mode OFF)

Graph ②: Graph for periodical monitoring has been added.


・FIBER LASER PROCESSING MACHINE
Visualizing gas and power consumption helps save running costs.

New feature

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17.3. Specified Period Running Status

Numerical value ①

Graph ①

Numerical value ①: Average/total values for idle time and set-up duration have been added.
Average calculation: Total value during the operation days is divided by the operation days.
Total calculation: Total hours or times during the operation days are displayed.

Graph ①: Running statuses are expressed in different colors.


Running Rate: Percentages of "Production" hours, "Idle" hours and "Set-up" hours out of
"Power-on" hours are graphically displayed.
Production hours: blue; Idle hours: yellow; Set-up hours: orange

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17.4. Daily Report 1 (report output: part number control,
control, list type)

Graph ①

Graph ②

New feature

Graph ③

Table ①

Table ②

Graph ①: Band graph for idle and set-up hours has been added.
By adding the idle hours and set-up hours, more details of production status can be seen.
Idle: Idle hours are displayed in yellow. (Status that machine is not producing with control
power ON and production mode ON)
Set-up: Set-up time is displayed in orange. (Status that machine is operating with control
power ON and production mode OFF)

Graph ②: Gas consumption has been added to the graph for periodical monitoring.
・FIBER LASER PROCESSING MACHINE
Visualizing gas consumption helps save running costs.

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Graph ③: Power consumption has been added to the graph for periodical monitoring.
・FIBER LASER PROCESSING MACHINE
Visualizing power consumption helps save running costs.

Table ①: Production control table per each part number has been added.
It will support you with your production control: You can check the machine, person, part
number, times and hours of production. And you can contrast the production plans and the
production results.

Table ②: Consumables control table has been added.


・TWISTER
By displaying the utilization rates on replacing, wrong usage can be avoided. And such
machine troubles as an abnormal torch can be judged.

See [17.2. Machine Running Status] section for details.

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17.5. Daily Report 2 (report output: part number control, band graph type)

Graph ①

Graph ②

New feature

Graph ③

Graph ④

Graph ①: Band graph for idle and set-up hours has been added.
By adding the idle hours and set-up hours, more details of production status can be described
on the daily report.
Idle: Idle hours are displayed in yellow. (Status that machine is not producing with control
power ON and production mode ON)
Set-up: Set-up time is displayed in orange. (Status that machine is operating with control
power ON and production mode OFF)

Graph ②: Gas consumption has been added to the graph for periodical monitoring.
・FIBER LASER PROCESSING MACHINE
Making gas consumption visualize can help save running costs.
Graph ③: Power consumption has been added to the graph for periodical monitoring.

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・FIBER LASER PROCESSING MACHINE
Visualizing power consumption helps save running costs.
Graph ④: Band graph of production control per each part number has been added.
Since production hours for each part number are displayed with the band graph, you can see
the machine, person, part number, times and hours at a glance.

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