From Downtime to Uptime: LMS & CNC Improve Efficiency with Smart Sensors
Technology Being Tested
Milling Chatter Monitoring System
An innovative, low-cost system developed by LMS for real-time, in-line monitoring of machining tool performance. The system uses sensors and software to detect tool wear and prevent failures, boosting production efficiency and quality assurance in CNC manufacturing environments.
Use case in a Nutshell
LMS (Laboratory for Manufacturing Systems & Automation, University of Patras) technology owner, and CNC Solutions early adopter partnered through the DIMOFAC Early Adopters Programme to deploy and validate a milling chatter monitoring system aimed at improving production efficiency and reducing tool-related downtime. CNC Solutions integrated this technology with LMS’s guidance to explore automation, predictive maintenance, and smart manufacturing benefits in a real industrial setting.
About the collaboration partners
The Laboratory for Manufacturing Systems & Automation Department of Mechanical Engineering and Aeronautics (LMS) at the University of Patras has implemented close-to-market services to external companies within the framework of the DIMOFAC project.
CNC Solutions is a company specializing in precision CNC (Computer Numerical Control) machining. They design and produce precision CNC parts and also operate the only CNC training center in Greece
Description of the Collaboration
Problem Addressed
Tool failure and lack of real-time visibility into machining performance were limiting efficiency and increasing costs for CNC Solutions.
Solution
LMS deployed a sensor-based chatter monitoring system at CNC Solutions’ production site. The system enabled real-time assessment of tool conditions using dedicated software.
Execution
LMS led the technical implementation and sensor setup.
CNC Solutions contributed operational context and machine access, facilitating a hands-on testbed.
Host Role (LMS)
Provided sensing technology, software integration, and technical support.
Beneficiary Role (CNC Solutions)
Implemented the solution and assessed its effectiveness in daily operations.
Results of the Colaborration
Improved Efficiency
CNC Solutions reported significant gains in production efficiency and process stability.
Tool Failure Prevention
The system allowed proactive detection and avoidance of tool damage, minimizing unplanned downtime.
ROI Potential
The solution is expected to deliver a full return on investment within two years.
Scalability
The technology was compatible with existing systems, requiring no specialized training.
Future Outlook
CNC Solutions plans to explore additional AI and IoT integrations for continuous improvement and strategic growth.
Testimonials
The implementation of the DIMOFAC solution has significantly improved our production efficiency, demonstrating its value in our operations
Our collaboration with the beneficiaries was seamless… Their engagement provided invaluable feedback, enriching our understanding of real-world applications.
Project info:
The use case DIMOFAC project which received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 870092, aiming to help factories implement a smart factory architecture that will allow them to be more reactive to a personalised demand and changing market dynamics.
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