Precision Manufacturing Inc.

The Challenge: Stagnant Efficiency and Reactive Maintenance

Precision Manufacturing Inc., a tier-2 aerospace supplier, operated a fleet of 12 modern CNC machines. Despite their advanced equipment, they struggled with an Overall Equipment Effectiveness (OEE) of 68% and an average of 127 hours of unplanned downtime per month. Data was collected manually, leading to inaccurate reporting and a purely reactive maintenance strategy.

The Solution: Implementing the CNC Insight SEMS Platform

CNC Insight was deployed to provide a unified data platform. The implementation focused on leveraging our patented Smart Efficiency Manufacturing System (SEMS) to drive improvements.

• Comprehensive Connectivity: All 12 machines (Haas, DMG Mori, Mazak, Okuma) were connected using a mix of MTConnect and OPC UA through our Edge Gateway.
• SEMS Algorithm Deployment: The core of the solution involved analyzing real-time data through SEMS to identify hidden inefficiencies and predict potential failures.
• ERP Integration: The platform was integrated with their JobBOSS ERP system, allowing SEMS to influence scheduling and procurement based on actual machine performance.

The Results: Data-Driven Transformation

The SEMS platform transformed their operations from reactive to predictive. By analyzing vibration and load data, the system provided early warnings for spindle bearing wear, preventing catastrophic failures. Real-time OEE tracking allowed managers to address micro-stoppages and optimize cycle times, directly leading to a 9.5% OEE increase. The system's insights into process variations also contributed to a scrap rate reduction from 3.2% to 2.1%.

Customer Testimonial

"CNC Insight delivered more than a dashboard; they delivered a new manufacturing philosophy. Their SEMS algorithm gave us the predictive power we were missing. We're no longer just fighting fires; we're preventing them. The ROI was clear within the first five months."