Applications Engineering Team
IoTFlows
Writes about monitoring specific machines and lines: CNC machines, injection molding, packaging lines, changeovers and part counts.
Articles
Machines and connectivity
How to find the real bottleneck on a packaging line
The machine that is stopped is often only waiting. Read the counts at each step to find which machine stopped the line first, and which one limits its rate.
Machines and connectivity
Measure the loss from mold and material changeovers
Mold and material changes cost every minute from last good shot to first good shot, purge included. Log them apart, price a week two ways, then pick a target.
Machines and connectivity
How to monitor stamping presses, stroke by stroke
Track strokes, parts per stroke, stops, die and coil changes and scrap on any press. Compare a frame sensor, exit beam and press control on a 40 SPM shift.
Operations and lean
Shift changeover losses and how to win them back
Shift change costs the stopped minutes on either side of each handover. Measure them against mid-shift, size a week on one machine, and pick the first fix.
Machines and connectivity
Part counting methods and which one fits your machine
Count parts from machine cycles, a beam break, the controller’s counter or a hand tally. Match a method to CNC, molding, presses and packaging, then check it.
Machines and connectivity
How a sensor knows a machine is running
A sensor tells running from stopped by comparing vibration or sound with two calibrated levels and ignoring brief swings. See how, and when to use the control.
Downtime and utilization
How to track machine downtime and its causes
Let a machine signal record every stop and ask operators only for the reason. A worked shift, rules that name routine stops, and a first-week checklist.
Machines and connectivity
Counting parts and cycle times on CNC mills and lathes
Count CNC parts and time each cycle from outside the control: what one cycle is, one operation per job, parts per cycle, and a hand count that proves it.
Operations and lean
Why reworked parts don’t count in first pass yield
Reworked parts aren’t good parts in first pass yield or OEE quality. Work FPY, final yield and scrap rate on one batch, and see why quality and scrap disagree.
Machines and connectivity
How to monitor a packaging line and count every unit
Count output after the last reject, take the ideal rate from the slowest machine, and find which filler, capper or labeler stopped first. With a worked shift.
Machines and connectivity
How to monitor injection molding machines
Count shots, multiply by working cavities and keep mold-open pauses out of downtime. Learn why a molder's count reads double or half, and how to check it.
Operations and lean
Measure changeover time before you try to cut it
Time changeovers from last good part to first good part, log internal and external work, and compare by type and median. A worked mold change shows how.