Find your machine, not your industry.
A gearbox behaves the same in a sugar mill and a cement plant. This index is organised by equipment, for when you know the machine but not which sector page applies.
This index is organised by equipment, not by industry. A gearbox behaves like a gearbox whether it drives a sugar mill or a cement kiln, and the signals that reveal its condition are the same in both. If you know what the machine is but not which industry page applies, start here.
Looking for your sector instead? The solutions index is organised by industry and production process.
Machine tools
Cycle structure differs sharply between these machines, and so does what counts as a stop. Each page is written for that machine rather than adapted from a template.
EDM
Long cycles, frequently unattended. Idle-time logic built for machining centres misreads both of these machines entirely.
Machines with no controller
Equipment that cannot report anything can still carry a signal — and these are usually the machines with the most unmeasured loss.
PLC-driven equipment
Where the data already exists in the machine's own logic, and the work is agreeing what it means.
Thermal equipment
No cycle, no part counter, and a completely different loss profile — dominated by time at temperature producing nothing.
Rotating equipment
Continuous-duty machines whose condition is written in vibration long before it appears in output.
Machine tools
Cycle-driven machines where the part count is the ground truth and setup is the hidden loss.
Thermal and process equipment
Batch machines where the loss is measured in held temperature and empty chamber time.
Test benches and rigs
Equipment whose output is a document: a test record that has to survive years of warranty.
Machine signals, an energy meter and sensors, on one timeline.
Every machine can carry all three. Each part is recorded with the energy it took and the condition of the machine that made it.
What the machine is doing
- State: running, idle, setup, stopped
- Counts and cycle time, per part number
- Stops with reasons from the operator
- Alarms and fault stops
What it costs to run
- kW, kWh, kVA and power factor, live
- Energy per part, per shift and per job
- Idle energy: power drawn while producing nothing
- Maximum demand and load profile
How healthy it is
- Condition sensors connected where they matter
- Per-machine baselines, not generic limits
- Alerts before a trend becomes a breakdown
- Readings stored against every part
Sensors typically connected on a machine
An energy meter connection is available on every machine type we monitor. Sensors are chosen per machine at the pilot, and connected by the MachineWise team. See energy monitoring and condition monitoring.