Summary :
A leading mold maker in North America, operating a fleet of 38 heterogeneous CNC machines (Hermle, Huron, Makino, Okuma, AWEA, OPS Ingersoll, etc.), deployed Atsora Tracking to efficiently structure and leverage its production data.
Before the project, visibility into the actual status of the machines was limited, the causes of machine stops were difficult to analyze, and tracking mold production progress required time-consuming manual processing. The objective was clear: transform raw machine data into reliable operational information that could be used in real time by both the shop floor and industrial management.
Without modifying existing CNC programs, Atsora Tracking collects and contextualizes data from a wide range of CNC controllers (Heidenhain, Fanuc, Okuma OSP, Selca, etc.). The solution provides real-time visibility into machine status, accurate tracking of operator-classified machine stops, a mold- and component-oriented view of production, and precise calculation of actual machine operating times.
As a result, the company achieved greater responsiveness, objective performance analysis, improved control over mold costs, and enhanced investigation capabilities to identify and address root causes. Machine data thus became a key driver of industrial performance.
Use case: Production tracking of a heterogeneous machine park at a reference mold maker
In an environment where lead times, quality, and profitability are critical, mold makers must now rely on accurate and reliable use of the data generated by their machine tools.
In this use case, we will show how Atsora Tracking helps a leading North American mold maker monitor and optimize its production without disrupting its existing operations.
Industrial context and challenges of the mold maker
A historical player in precision molding
Founded in the 1970s, Cavalier Tool & Manufacturing is a renowned mold maker with multiple production facilities across Canada and a large fleet of machine tools.
Its business is based on manufacturing complex molds, requiring full control over machine times, machining sequences, and the causes of production disruptions.
The challenges identified before deployment
Before implementing Atsora Tracking, the company faced several challenges common to many mold makers. Visibility into machine status was limited, the causes of machine stops were not always clearly identified, and the actual progress of mold production was difficult to monitor in real time. In addition, accurately calculating machine time for each mold or component required time-consuming manual processing, limiting the use of data to retrospective analysis.
The objective was therefore clear: to transform raw machine data into usable information, directly useful to field teams as well as industrial management.
Implementation of Atsora Tracking in the workshop
Connection of the machine park
Atsora Tracking is deployed across a fleet of 38 CNC machines.
Cavalier Tool's machine fleet is highly diverse, both in terms of machine manufacturers and CNC controllers. It includes 3-axis and 5-axis machining centers, large gantry machines, deep-hole drilling machines, and lathes from leading European and Asian manufacturers such as Hermle, Huron, Makino, Okuma, AWEA, and OPS Ingersoll.
The management environments are just as varied, with a coexistence of Heidenhain, Fanuc, Okuma OSP, Selca controls, as well as specific architectures integrating hardware modules or serial connections.
Atsora Tracking automatically collects data from the machines without modifying existing CNC programs and transforms it into actionable operational information.
The goal is not to monitor people, but to provide teams with greater visibility and the context they need to make better decisions.
Real-time production tracking
Immediate visibility on the status of the machines
With Atsora Tracking, shop floor managers have access to a dedicated dashboard displaying the real-time status of every machine. This live view instantly shows whether a machine is running, stopped, idle, or in an abnormal condition. It also displays the molds and components currently being machined, along with operating speeds and machine modes.
This real-time visibility significantly improves team responsiveness by enabling rapid identification of situations that require intervention.
Continuous improvement and analysis of downtimes
Understand to better prioritize
Atsora Tracking provides accurate monitoring of machine stops, with operators classifying the causes directly on the shop floor. This operator input adds essential context to the raw machine data, making performance analysis far more meaningful.
This enables teams to identify the main sources of performance losses, prioritize corrective actions, and track the impact of implemented improvements. Dedicated reports support continuous improvement initiatives by providing objective, shared performance data.
Progress tracking and CAM planning
A mold and component-oriented reading
One of the key priorities for a mold maker is knowing exactly where each mold stands in the production process. Atsora Tracking structures production data around a clear operational framework, linking machine data to molds, components, operations, and machining sequences.
This approach provides reliable, real-time production tracking while giving CAM teams greater visibility to adjust production planning. Dedicated dashboards improve coordination between programming and the shop floor, reducing misunderstandings and eliminating unnecessary delays.
Control of production times and costs
From actual machine time to cost per mold
By automatically linking machine data to the machined components, Atsora Tracking accurately calculates the actual machine time for each mold. This information is essential for analyzing production costs, comparing planned versus actual performance, and improving the accuracy of future estimates.
The data can also be exported to business intelligence tools such as Power BI, enabling production metrics to be combined with financial and organizational data for more advanced analysis.
In-depth analysis of problems
Going beyond the symptom
When an issue occurs, Atsora Tracking provides detailed analysis tools that allow users to drill down step by step from an overall view to the specific machining sequence involved. Machine alarm reports, combined with component-specific machine stop reasons, provide a detailed understanding of the underlying issues.
This in-depth investigation capability enables technical teams to identify and resolve root causes rather than simply addressing the visible symptoms.
Observed results
By implementing Atsora Tracking, the mold maker gained greater visibility, responsiveness, and control over its production. Decisions are now based on reliable, contextualized, and shared data across teams. The intelligent use of data from high-performance machine tools, such as Huron machining centers, has become a true driver of industrial performance.
Atsora Tracking, at the service of mold makers and complex machining
This use case demonstrates Atsora Tracking’s ability to transform machine data into actionable operational information for machining workshops and mold makers. With its practical, shop-floor-oriented approach, the solution goes beyond simple machine monitoring to deliver lasting improvements in industrial performance.
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