Velonex (Accuratech)
Manual OEE tracking on mixed-age CNC machines masked real productivity losses (reporting 78% vs. actual 56%). Velonex’s 24/7 monitoring exposed true performance and enabled real-time corrective action.
Problem Statement
Accuratech needed to boost throughput and cut overheads within existing capacity, but unified tracking was hindered by 5 machines ranging from 1 to 10 years old with diverse CNC controllers like Mazatrol and Fanuc. Furthermore, manual OEE tracking concealed true operational losses by generating overly optimistic performance metrics that misled management. Without real-time visibility into machine downtime, the company could not systematically identify bottlenecks or make data-driven decisions to increase productivity.
Solution
Velodynamics deployed Velonex an Industry 4.0 monitoring system offering 24/7 OEE tracking and designed two hardware approaches (Siemens-PLC with HMI and TID via RS-232/Macro-B). To test the technology, Accuratech launched a pilot connecting three top-performing machines using the TID approach via LAN to a centralized computer. This setup delivered continuous real-time data to PCs, tablets, and mobile devices, empowering operators and managers to take immediate corrective actions on the shop floor.
Functionalities
Overall Equipment Effectiveness (OEE)
Tracks true productive manufacturing time, pinpoints underlying losses, and guides systematic process improvements.
Statistical Process Control (SPC)
Live performance monitoring that detects process shifts before non-conforming products or scrap are produced.
Product Traceability
Automated real-time tracking of product location, status, and availability across manufacturing stages via Barcode, QR Code, RFID, or Laser Engraving.
24/7 Remote Visibility
Real-time dashboards and analytics accessible anytime from PCs, tablets, or mobile devices across the globe.
Tech Stack
Layer
Technology Stack
Frontend
Angular
Backend
.Net core 8
Database
MSSQL
Cloud & Hosting
Amazon Web Services
Notifications & Services
Firebase Cloud Messaging (Mobile Application) / MessageHUB / SignalR
Impact on Client
Exposed True OEE
Within 3 months, Velonex revealed that the actual OEE was 56%, debunking the manual, overly optimistic estimate of 78%.
Immediate Capacity Recovery
Real-time alerts allowed fast, corrective actions on the shop floor, preventing critical loss of production hours.
Minimized Waste & Cost
Shorter rework loops and reduced scrap directly reduced unit manufacturing costs and raised overall plant profitability.
Testimonials
"Velonex has transformed how we track machine availability and analyze shift downtimes throughout the day. It gives us full visibility into production even during the night shift and allows us to generate comprehensive reports on both production and quality metrics. Velodynamics’ expertise in designing and developing Velonex truly showcases their commitment to excellence, making them an invaluable partner in our drive toward efficient production management."
Amar Jadhav
CEO
ZP
October 2022
