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Manufacturing Machinery and Process Monitoring

As reported by Quality Magazine, “As energy becomes more expensive and sustainability more prized, manufacturers are under the gun to reduce energy consumption. Process monitoring, which standardizes and optimizes manufacturing processes— helps to make this possible in the age of Industry 4.0.”


Process monitoring provides inline quality control, quickly catching defects in the manufacturing process, reducing machine, material, and labor cost, and improving profitability by continuously increasing the production of quality parts.

Modern process monitoring solutions include equipment that is flexible, sustainable, easy to operate, and requires minimal (if any) human interaction. Sensors collect accurate and real-time data that can be shared through interconnected machine tools. This all contributes to a complete overview of the factory and helps determine the overall state of wellness across the entire manufacturing process.

Process monitoring measures what is happening during every second of production.  Process statistics are recorded and monitored for deviations allowing for the identification of events that are trending poorly, predicting the production of bad parts. Process monitoring is also a useful tool for root cause analysis.

A common, day in the life, scenario looks something like this:

  • A production order for a 50,000 item job is making its way through the factory
  • Only 1,000 items in, a process monitoring alert is activated
  • The alert notifies the supervisor that the production rate has slowed, and the job is not predicted to complete on time
  • The alert also notifies an engineer who examines the process monitoring data and notices the spindle speed of the machine is at unacceptable levels
  • The production supervisor immediately moves the order to a different piece of equipment
  • The engineer reviews the production, quality, and process data and determines the root cause of the failure

Process Monitoring is like a weatherman for your factory, looking out for signs of looming storms that can develop, identifying patterns, and issuing necessary warnings. For manufacturers, the timeliness of catching poor production performance is key.

When considering a process monitoring solution, don’t forget the importance of developing critical requirements for the system upfront. Make sure you know the operation’s current procedures before starting to evaluate potential monitoring systems. It pays off to have project team members who perform the job. They can provide details that are often overlooked by those who are not hands-on.

If you are challenged by a lack of real-time visibility into Machine State, Quantity, Temperature, and Alerts, Contact ShopVue to learn more.