How SensFlo Helps High-Value Job Shops Measure & Monitor Spindle Hours

‍Introduction

In the high-stakes world of precision manufacturing, maintaining efficiency and transparency is crucial. SensFlo, an industry leader in AI-driven solutions, partnered with Miller CNC to implement an advanced machine monitoring system. This collaboration aimed to enhance productivity, optimize resource allocation, and provide real-time insights into shop floor operations. Here’s how SensFlo transformed Miller CNC’s operational efficiency.

Company Background - Miller CNC

Established in 2007, Miller CNC specializes in 5-axis and hard metal machining, serving primarily the aerospace industry. Based in San Diego, this AS9100 & ISO 9001 certified machine shop is renowned for its technical expertise and dedication to exceeding customer expectations.

Challenges

Despite their growth, Miller CNC faced several operational challenges:

• Machinists were too busy to report activity at the machine level.
• Accurately evaluating setup time for each job was challenging.
• The shop floor manager was overwhelmed with repetitive tasks, limiting their ability to monitor productivity thoroughly.
• The shop owner needed precise equipment utilization data to plan resource allocation and pricing effectively.

Approaches

1. Installing Machine Monitoring Solutions

SensFlo began by installing monitoring solutions across all machines in Miller CNC’s three primary sectors: lathes, 3-axis, and 5-axis milling machines. Network-connected machines utilized a single IoT device, streamlining the data uploading process.

2. Utilizing AI-powered Dashboards

SensFlo provided an intuitive dashboard that allowed Todd Cuffaro, the shop owner, to monitor daily, weekly, and monthly machine statuses. This tool provided comprehensive transparency into machine utilization and job durations, helping identify bottlenecks and optimize operations.

3. Weekly Summaries and Alerts

SensFlo sent weekly summary and alert emails to Todd and the shop manager whenever machine utilization was low. These reports included spindle hours and shop floor visualizations, aiding in better archiving and management.

4. ERP Integration

Integrating SensFlo’s solution with Miller CNC’s on-premise ERP system, Shoptech E2, eliminated many repetitive tasks. This seamless integration enabled real-time tracking and analysis of spindle hours by department.

Results

1. Increased Productivity

Within two months, Miller CNC saw a significant increase in productivity, generating $30,000 worth of productivity per month and achieving a 29x ROI. The integration provided better transparency and efficiency in machine utilization and personnel performance.

2. Enhanced Machine Utilization

SensFlo’s monitoring solution enabled Miller CNC to maintain over 50% machine utilization, far exceeding the industry average. This improvement was driven by accurate real-time data and proactive management strategies.

3. Streamlined Operations

The AI-powered system allowed Miller CNC to identify and address potential issues before they affected production. This proactive approach reduced downtime and enhanced overall shop floor efficiency.

Conclusion

SensFlo’s AI-powered machine monitoring solutions have significantly improved Miller CNC’s operational efficiency. By delivering real-time insights, accurate productivity projections, and seamless integration with existing systems, SensFlo has helped Miller CNC achieve remarkable gains in machine utilization and overall productivity. If you aim to optimize your manufacturing processes and ensure consistent productivity, SensFlo’s advanced AI solutions are your key to unlocking full potential.