Velonex (PCL)
The same blind spot in manual OEE reporting (76% claimed vs. 58% actual) hid downtime losses across aging CNC machines. Velonex’s real-time dashboards gave the shop floor accurate, actionable visibility.
Problem Statement
Precision Campshaft Ltd 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, PCL 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 12 months, Velonex revealed that the actual OEE was 58%, debunking the manual, overly optimistic estimate of 76%.
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 revolutionized how we monitor machine uptime and pinpoint shift-wise downtime in real time, giving us total operational clarity even overnight. It streamlines our production and quality reporting while delivering actionable insights every single shift. The technical precision Velodynamics brought to building Velonex proves their commitment to quality, making them a trusted collaborator in driving our manufacturing efficiency forward."
Vishal Karbhari
Plant Incharge
ZP
June 2022
