Why Precision Manufacturers Don’t Use Machine Monitoring

In an industry built around precision, many facilities have yet to implement an automated production monitoring system. Most rely on manually collected data at the end of the shift, which is tracked in spreadsheets or an ERP. The most commonly collected data include date, job name, operator, shift, hours, parts made, and parts per hour—all important factors to track what has been produced. The problem is that those facts don’t help manufacturers figure out how to Make More.

What is Machine Monitoring?

Machine monitoring, often referred to as production monitoring, is just what it sounds like—technology that monitors what a machine is doing on the production floor. It has been around for decades and started as simply monitoring whether a machine was on or off. Over the years, it has become more sophisticated as CNC machines got smarter. Then, other monitoring companies started gathering more data from the machines augmented by operator input. While better than the on/off model, these systems still require people to spend a significant amount of time either entering data or manipulating it to gain insights. Next Gen Monitoring Solutions, such as Datanomix, pull real-time, raw data directly from the CNC controller and then analyze and organize the data into user-friendly dashboards, available across connected devices like smart TVs, mobile phones, tablets, and laptops.

Having real-time and historical insights into production performance is a real game-changer. So why hasn’t every facility adopted monitoring? The reasons seem to fall into the following categories: 

Questions Around ROI?

Doubt around whether the benefits of increased uptime and efficiency outweigh the costs and effort of implementation. Some believe the process of implementing monitoring software is comparable to implementing an ERP system. Spoiler alert, it’s not. The most skeptical are the manufacturers that tried earlier monitoring solutions that didn’t deliver the ROI they were promised, and rightfully so.

Datanomix Difference: Customers love Datanomix. We don’t just take your money and run. Your dedicated customer success team completely manages your no-downtime implementation. It includes training on the software and best practice coaching for driving change using data. The average ROI is an additional hour of uptime per machine per day, achieved by implementing Quick Wins. Many of our customers switched from other systems and are blown away by the difference. Want an idea of your ROI? Here’s a calculator

Integration Challenges?

For many, the primary point of reference for implementing production or machine monitoring is an ERP system, which can be complex. ERPs and Production monitoring are very different. Production monitoring solutions need to connect to your machine controllers; that’s it. It takes hours to set up the system, not months or years.

Datanomix Difference: Your dedicated Customer Success Team (CST) manages the installation process for you. They ensure that every machine is hooked up and delivering good data before you “go live”. No IT department required! Datanomix has connected thousands of machines and is compatible with all makes and models of modern CNC machines.

Resistance to Change?

Change is hard. In the past, concerns that employees will think that “Big Brother” is watching have contributed to the slow adoption of machine monitoring. However, this is changing as leaders in manufacturing are adopting data automation more quickly to ensure they remain competitive. Operators are also embracing the technology because it provides immediate feedback on their actions and supports their claims about the changes that need to be made to the program.

Datanomix Difference: Change is hard, but we make it easier by starting you out with three simple workflows. Our Quick Wins Program introduces the team to the power of real-time data. Once everyone can see the impact their actions have on meeting goals, they embrace the system. We believe that everyone wants to do a good job, and when they have the information they need to succeed, they do! We also coach the leadership team on how to address the “big brother” concerns from the outset.

Too Busy?

Busy managers can’t see how they will have time to add one more thing to their plate, and operators don’t want another thing to do either. Ironically, monitoring is perceived as more work, rather than a means to be more efficient.

Datanomix Difference: Datanomix takes things off people’s plates, like chasing people, paper, and parts to populate spreadsheets. Plant operation managers tell us they get back an hour a day! And Datanomix requires No Operator Input. Operators can spend 100% of their time running their machines, not writing down part counts and reasons for downtime. Additionally, our Prescriptive guidance outlines industry best practices that help facilities streamline their processes.

Here’s how every person in your facility could use Datanomix to drive daily decisions.

Stressed About Data Security?

Concerns about cybersecurity and the risks of a data breach make people wary about putting their machine data “in the cloud”.

Datanomix Difference: We help our customers comply with the U.S. Department of Defense (DoD) Cybersecurity Maturity Model Certification (CMMC) and the National Institute of Standards and Technology (NIST) Special Publication (SP) 800-171. Our flexible architecture enables us to quickly implement new security requirements, helping to thwart those targeting US manufacturers. In many cases, we help customers enhance their cybersecurity because they lack a dedicated IT team.

Think Good Enough Is Good Enough?

Some facilities believe their current manual process is sufficient and see no immediate need to change.

Datanomix Difference: If a company is satisfied with “good enough,” they are probably not a good fit for Production Monitoring. Customers choose Datanomix because they want to Make More. Good enough isn’t an option.