SENSO AI assistant

SENSO – Your Smart Assistant for CNC Production Evaluation

SENSO is a new integrated service within the CNC Sensor system that uses artificial intelligence to evaluate production data from CNC machines. Based on daily aggregated data, it provides a clear and technically accurate assessment of each machine individually – including a concise overall summary. The result is immediately sent to the email of the production manager, operations supervisor, or company owner.

How Does It Work?

Daily automatic evaluation of data from each CNC machine
A short, factual summary instead of complex tables and charts
Overall recommendations to increase production efficiency
Results are delivered daily via email or available directly in the CNC Sensor interface

Key Benefits:

Instant overview of the status of each machine
Technical recommendations directly applicable for production optimization
Saves time when analyzing production data
Highly understandable even for company leadership

Who Is SENSO For?
For anyone who needs to quickly and efficiently understand what’s happening in the workshop – without lengthy report reading:

CEOs and owners of manufacturing companies
Production managers and process engineers
Shift leaders and shop floor supervisors

Example of output from the SENSO AI assistant

Machine: Mazak i600
Uptime: 1051.5 minutes
Comment: Main program 26387 (401.5 minutes, 24 pieces) shows very good utilization (76.7%), low downtime (16.5%), and serves as an example of efficient medium-batch production. Other programs (especially 28616 and 28616-FORMAT) show extremely high shares of setup and alarm times (up to 78% setup for FORMAT), mostly producing only 0–3 pieces. Short programs like 28616-SONDA are non-productive and used for measurement or inspection.
Recommendation: Focus on reducing setup times for single-piece and small-batch production by integrating off-machine preparation, or consider moving less efficient jobs to a different workstation/machine where utilization will not impact the main program's production. Assess the necessity of frequently running inspection or measurement cycles during the shift.
Scrap rate: 0.0%

Machine: Mazak 100
Uptime: 954 minutes
Comment: The highest utilization was achieved by program 31393 – a medium-batch production (232 pieces) with an average utilization of 76.2%, indicating efficient deployment, although downtime was 23.0%. Other programs (1-1, 19891, 31397, 32274) represent small-batch or one-off production with very low utilization (5.8–27.2%) and high shares of downtime (46.8–85.4%) and setup (3.1–54.4%), indicating frequent changeovers and low efficiency outside the main batch. A significant alarm in program 19891 (3.5%) suggests a partial malfunction, and program 32274 shows extremely high setup time (54.4%).
Recommendation: For smaller batch production, optimize NC programming, improve off-machine tool and fixture preparation, and utilize a modular system. To reduce downtimes between programs, implement more precise shift and operator scheduling based on qualifications, and accelerate presetting of fixtures and tool sets. It's recommended to review and align the operation sequence. NC programming should be complemented with simulation to reduce alarms.
Scrap rate: 0.0%

Daily Summary:
The analysis of the monitored day indicates overall low efficiency of the CNC machining centers, with a high share of downtimes and time-consuming setups, particularly on machines VCN 510, Tajmac MCV1220, Mazak 250, and Doosan Lynx 220. In these cases, single-piece and small-batch production proved inefficient and was often non-productive, suggesting issues with logistics, tool management, and setup processes. The only exceptions were the Mazak i600 and Mazak 100 during medium-batch production, where solid utilization and efficiency were achieved. On the Mazak 200 and TOS UB25 machines, there was no production throughout the day.

Recommendations:
Implement standardization of setup procedures, expand off-machine preparation of tools and clamping, introduce modular clamping systems, and improve production scheduling with an emphasis on group technology. Additionally, operator training needs to be enhanced, NC programs optimized, and production tracking for each machine closely monitored.

To ensure better utilization of Mazak 200 and TOS UB25, their role in the production plan should be verified, and in the case of extended downtime, consider maintenance or proper configuration of the piece counter.

Overall, internal logistics should be monitored and optimized, setup and downtime durations reduced, in order to increase productivity and the economic efficiency of manufacturing processes.

SENSO AI assistant

SENSO – Your Smart Assistant for CNC Production Evaluation

Example of output from the SENSO AI assistant

Would you like to see a live demo or discuss how the AI assistant could be used in your operations?

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