Solutions - machine monitoring system
Leanworx machine monitoring system gives you data from your machines 24/7, enables you to improve manufacturing profits by reducing waste of machine capacity, and improving OEE. It gets accurate and timely data from your machines to your computer network, and shows you information that you can act upon. It also has interfaces to all your other software and hardware like ERP, maintenance, logistics, etc. to give them accurate and instant data.
To CNC machines via ethernet, on protocols like MTConnect, OPC-UA, or Fanuc Focas and other proprietary protocols. Data goes through broadband to Leanworx cloud server.
To CNC machines via relays in the electrical panel, using Leanworx IoT tracker direct to Leanworx Cloud server, with no IT infrastructure required.
To PLC based machines via ethernet, on Modbus protocol.
To electro-mechanical or manual machines via signals from inexpensive retrofitted sensors. is an
Machine monitoring system for any machine
Use Cases
Leanworx works in a variety of manufacturing industries: Automobile parts, Aerospace parts, Pumps, Farm equipment and Off-road vehicles, Gear manufacturing, Springs manufacturing, Foundry, Forging plant, Plastic, Injection moulding, Packaging.
Leanworx benefits - real stories
Story 1: Auto parts maker - downtime at shift change eliminated (14% of available time)
Before Leanworx
Before the CNC machine monitoring monitoring system was implemented, in every shift the production started late and ended early. Highest downtimes were at the end of the 2nd shift, and start and end of the 3rd shift. Average downtime was 1 hour per shift, reducing production capacity by 12%.
After Leanworx
After CNC machine downtime monitoring was started, the downtime dropped by about 25 % on its own, without any action, 2 days after Leanwox was connected to all machines. In 3 weeks the downtime reduced to less than 5 minutes per shift. Production quantities increased proportionately, by 12 %.
Story 2: Auto parts maker - OEE improved 23% in 5 months
Before Leanworx
OEE varied from 32 % to 65 %, depending on the type of machine. CNC machines were the lowest.
Marco Verch CC BY 2.0
After Leanworx
Through use of the OEE monitoring system in Leanworx, OEE improved by 23 % on CNC machines, 15 % on foundry machines. Result: higher profits because of higher production quantities with the same number of machines, lower cost of production per part, lower rejections, reduced raw material cost.
Story 3: Profits improved by paying operator incentives from production monitoring
Before Leanworx
Operators were being paid fixed salaries irrespective of their productivity. Good operators felt unrewarded, and bad operators were not being penalised. Factory efficiency was being impacted badly.
After Leanworx
Using data from Leanworx machine monitoring system, operators are paid incentives based on production quantities and efficiency from machine operator efficiency monitoring reports. OEE improved by 19 % in 3 months. Savings: Rs. 38,000 per machine per month. Operators resigning reduced by 42 % in 3 months.
Story 4: Manufacturer of tractor parts postponed buying new machines by 2 years
Before Leanworx
Downtime was 46 % of total available time.
After Leanworx
Using data from the machine monitoring system, achieved such a rapid machine downtime reduction that they postponed buying 18 machines costing Rs. 5.6 Cr., by 2 years. Even though orders were increasing by 15 % a year.
Downtime was reduced to 22 % in just 5 months, and then dropped further over 2 years.
Story 5: Aerospace parts manufacturer stopped working 3rd shift
Before Leanworx
Machines ran 24 hours, with 3 shifts of 8 hours each. Spindle was running 30% of the time.
After Leanworx
With machine data monitoring, the firm shut down 3rd shift working by doing the same number of parts in 2 shifts. Spindle is running 64% of the time.
This happened in 7 months.
Story 6: Pumps manufacturer - simple fix resulted in BIG profits
Before Leanworx
In a bay with 8 HMCs, there was a one hours downtime every day on every machine, for the reason ‘Waiting for tool’. Each machine cost Rs. 1000 per hour, so this was a loss of about Rs. 26,000 per machine per month.
After Leanworx
After the machine monitoring software was installed, downtime for this particular reason reduced to zero, for all 8 machines. Effectively, eliminating 1 hour downtime every day means they got a capacity increase of about 4 % with the same capital investment.
Story 7: Springs maker knows production quantity, that was earlier unknown
Before Leanworx
There was no accurate production tracking. Resulted in over-production causing excess inventory and increase in inventory holding cost; under-production causing delivery delays; inability to schedule properly.
After Leanworx
Production monitoring system counts the actual number of parts made, at any instant. Reports show hourly and shift-wise production. Over-production and under-production have been eliminated, leading to lower inventory costs, better scheduling, improvement in profitability.
