Broadening your machine monitoring strategy allows your operations to shift from a disconnected silo to an integrated, data-rich narrative in which every machine can talk, and every team can listen.
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The Machines You Didn’t Think Could Talk

Factories today tell a story in two halves: a tale of gleaming, modern CNC machines streaming data to dashboards, paired beside older, time-tested equipment that hums reliably but remains invisible in the eyes of digital monitoring systems. This schism is more than just technological nostalgia; it’s a blind spot costing manufacturers in ways they may not realize, as revealed in Scytec Consulting’s recent webinar, “Machines You Didn’t Know You Can Monitor.”

The Hidden Side of the Shop Floor

Step into any production facility and the contrast is clear. While the latest machines report their every move in real time, legacy mills, fabrication lines, robot cells and even conveyor belts and pumps operate undetected in the data landscape. These machines, lacking modern interfaces, are often sidelined, assumed too challenging or insignificant to monitor.

Legacy equipment monitoring isn't often a priority, as older machines are assumed too challenging or insignificant to monitor. But the cost of their invisibility accumulates.

Legacy equipment monitoring isn’t often a priority, as older machines are assumed too challenging or insignificant to monitor. But the cost of their invisibility accumulates.

But the cost of their invisibility accumulates. OEE (Overall Equipment Effectiveness) metrics become skewed, operational bottlenecks stay hidden and teams are caught off guard by downtime events cascading from an unmonitored corner of the shop. For IT managers, partial visibility can undermine confidence in analytics. For operations leaders, unexpected downtime remains a persistent mystery in which the root cause has yet to be fully identified.

Enabling Every Machine to “Talk”

The paradigm is shifting – thanks to advances in edge devices and versatile data collectors. Today, relays, signal converters and IoT sensors can harvest signals from even analog presses and decades-old mills. Ethernet isn’t the dividing line; devices can now translate run/stop signals, power use and vibrational cues into actionable intelligence. The Scytec webinar demonstrated that the tracking of an elevated temperature of thermocouples can trigger graduated alarms to key stakeholders on and outside of the shop floor. These alarms can prompt actions to decipher likely causes and next steps for the operator, maintenance and management for continuous improvement.


These innovations turn the challenge into opportunity. IT departments can transition from mere system guardians to champions of digital transformation, unlocking insights previously lost in the noise of unending support tickets, safeguards against ransomware, upskilling staff and so on. Operations teams, in turn, gain a richer, more complete perspective to underpin scheduling, planning and maintenance strategies – helping to answer the perennial questions of “How much capacity do I have?,” “Should I buy a new machine or hire more, and when?” and “Is this machine underutilized or better applied elsewhere?”

 

Even older conveyor belts and pumps can operate undetected in the data landscape without proper legacy machine monitoring.

Even older conveyor belts and pumps can operate undetected in the data landscape without proper legacy machine monitoring.

Prioritizing Legacy Equipment Monitoring

Given the flood of urgencies occurring on the floor each day, why does this matter now? There are three forces changing the game today:

  • Rising cost pressures: Margins across manufacturing sectors are narrowing due to tariffs, continued inflation and a tight skilled labor market, making blind spots in downtime and performance increasingly expensive. Over 70% of CEOs polled by Chief Executive agreed that increasing costs is their top challenge in 2025.
  • Simpler retrofits: What once required bespoke engineering can now be achieved with off-the-shelf hardware and rapid deployment with the expertise of a manufacturing integrator, like Shop Floor Automations. A well-established integrator enables manufacturers to not only source, vet and implement equipment monitoring solutions – but provides the in-depth service and support to properly wire PLCs into machines, such as a Haas Style 2/3 Light Tower.
  • Clamor for deeper data: Boards and executives are demanding sharper insights into OEE and capacity, in which partial answers (or “I don’t know” responses) are no longer acceptable. Harvard Business Review details how AI is now empowering the decision-making process of boards. “The board of one steel company used AI-generated simulations to help it decide between investing in an existing production facility or building a mill in a new geography,” wrote authors Stanislav Shekshnia and Valery Yakubovich. Data can be made available throughout the enterprise; now it’s a matter of who, what, when, how and why.

The ROI becomes tangible as more machines join the network: surprises diminish, planning gains precision and proactive maintenance can catch issues before they become costly crises. “We’ve seen an approximate 10% increase in efficiency across the board,” says Reyes of his machine monitoring approach at MOGAS, a manufacturer of severe service ball valves for industrial applications.

Retrofitting legacy equipment for monitoring has become simpler, thanks to advances in off-the-shelf hardware and rapid deployment from manufacturing integrators, like Shop Floor Automations.

Retrofitting legacy equipment for monitoring has become simpler, thanks to advances in off-the-shelf hardware and rapid deployment from manufacturing integrators, like Shop Floor Automations.

Take Action

To start exposing your blind spots, Scytec provided the following recommendations for manufacturers with a mix of legacy and modern equipment on the shop floor today:

  1. Audit your shop: Spotlight machines that currently fly under the radar.
  2. Target quick wins: Focus first where downtime creates clear pain.
  3. Run pilots: Test solutions on a small cell or line before a full rollout.
  4. Validate and expand: Confirm the data’s accuracy, then scale methodically while keeping operators in the loop.
  5. Value incremental progress: Even modest expansions can quickly uncover hidden inefficiencies and deliver payback.

The Future: Connecting Old and New

True smart manufacturing isn’t just defined by the newest, shiniest equipment on the floor – that simply isn’t cost-effective for most manufacturers. Smart manufacturing is built on bringing every piece of the fleet, old and new, into the conversation. Each previously unmonitored machine adds a vital clue to the puzzle of shop floor performance.

As manufacturers broaden their monitoring strategies, the story shifts: from disconnected silos to an integrated, data-rich narrative in which every machine can talk, and every team can listen. Contact manufacturing integrator Shop Floor Automations to explore your connectivity options today.

DNC hardware device setup
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3 Hidden Dangers of Improperly Installed Devices on the Shop Floor – Part 2

Cybersecurity, Downtime and What You Can Do About It

In Part 1, we covered how the rush to install low-cost DNC program transfer devices can create real electrical hazards and safety risks on the shop floor. But the threats don’t stop there. When improperly installed, these devices can also expose your systems to cyberattacks, data corruption and expensive production downtime.

 

Let’s break down the next two hidden dangers.

 

Danger #2: Cybersecurity Vulnerabilities

“Attacks against Ethernet ports,” writes Lee Neitzel and Gabe Faifman in the International Society of Automation (ISA) blog, “usually try to exhaust buffer space or processing capabilities of the network interface card or its associated communications software. These attacks may be intentional or unintentional, such as a network storms or network scans that are configured to run too rapidly.”

 

RS232 Port on CNC for DNC hardware setup

RS232 ports, like the one shown, can provide a “back door” into CNCs for malware or errors that result in incorrect part programs, parameter tampering or hidden logic bombs in G-code.

Shops that lack robust network policies are especially vulnerable. Older machines rarely include built-in security features, and many manufacturers fail to control or disable unused Ethernet ports. Without monitoring, malware can move from the enterprise network to shop floor devices, corrupt G-code, or give unauthorized users access to machine controls. And when operators aren’t trained or processes aren’t standardized, those risks only grow.

 

Danger #3: Downtime, Lost Programs and Productivity Setbacks

Ironically, installing DNC hardware devices to increase efficiency often leads to lost time when best practices are skipped. Common causes of these failures include devices not being correctly configured to match the CNC machine’s baud rate or parity settings, lack of durability under real-world shop conditions (such as exposure to high temperatures, dust or coolant mist) and insufficient operator training in file handling and transfer protocols.

 

Additionally, when IT and engineering teams are excluded from the DNC hardware setup process, there is often no oversight of whether best practices or internal standards are being followed. As a result, basic oversights, such as misnamed files, unsupported transfer formats or missed firmware updates, can halt production, require rework or damage tools and fixtures. Such errors may seem minor, but over time, the accumulation of these setbacks erodes efficiency and morale. The good news is that these are entirely avoidable issues if the device implementation is approached as a strategic investment, rather than a quick fix.

CNC program hardware transfer device installation

For manufacturing IT and operations leaders, ensuring that DNC hardware is installed safely, securely and professionally is not just about keeping machines running – it’s about protecting your people, data and bottom line.

Planning for Protection and Security

The key to mitigating these risks lies in treating DNC system hardware setups with the same level of rigor applied to any other industrial system. This begins with investing in industrial-grade hardware designed specifically for use with CNC equipment. Devices should include features like electrostatic discharge (ESD) protection, high-durability enclosures and shielded cabling. Choosing cheap or consumer-grade components may save money upfront, but the long-term risks and performance issues quickly outweigh the benefits.

 

Older machines rarely include built-in security features, and many manufacturers fail to control or disable unused Ethernet ports. Without monitoring, malware can move from the enterprise network to shop floor devices, corrupt G-code, or give unauthorized users access to machine controls.

 

Equally important is the involvement of cross-functional teams in the planning and deployment process. Projects that include IT, operations, maintenance and safety stakeholders tend to yield better outcomes because each discipline brings unique expertise – whether it’s ensuring cable routing complies with OSHA 1910.305, planning for device accessibility during routine service or ensuring sufficient clearance and ventilation. When teams collaborate, they create an environment where both technical and frontline personnel understand correct usage, maintenance protocols and early warning signs of trouble.

 

From a cybersecurity perspective, “devices should be required to pass a recognized communication robustness certification, such as Achilles Communication Certification,” recommends Neitzel and Faifman. “These certifications use a battery of tests to verify that network ports and their communications software have been implemented to withstand high traffic rates and malformed packets.”

 

Physical security also matters. DNC file transfer hardware should be mounted in tamper-proof, vibration-resistant locations with clear labeling to assist in troubleshooting and maintenance. Cable runs should be managed to avoid strain, tangling or obstruction of moving machine parts. These details may seem minor, but together they form a strong foundation for safe, stable and compliant CNC integration.

 

CNC program transfer processes can streamline operations, but only if implemented with the same care applied to the machines themselves. For manufacturing IT and operations leaders, ensuring that hardware is installed safely, securely and professionally is not just about keeping machines running – it’s about protecting your people, data and bottom line.

 

Assess Your DNC Hardware Setup Today

Talk to a manufacturing integrator technician or request an audit of your current DNC hardware setup to ensure you’re not putting your operations at risk by contacting Shop Floor Automations today. The convenience of DNC hardware devices should never come at the expense of your people, your data or your productivity.

CNC machine maintenance work
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3 Hidden Dangers of Improperly Installed Devices on the Shop Floor – Part 1

Why DNC Hardware Convenience Can’t Come at the Cost of Safety and Uptime

Network-based CNC program transfer devices, like Wireless Connect or Wired Connect, have become indispensable tools for modern manufacturers. These devices streamline the transfer of CNC programs from desktop or laptop computers directly to machines, eliminating the need for legacy memory systems like floppy drives and PCMCIA cards. Manufacturing professionals recognize the time, effort and expensive OEM memory upgrades spared as a result of such hardware. “[They] definitely saved us a lot of time, a lot of money, from having to run around and do it with a laptop, especially on a lot of the older units that have the floppy drives in them, or the PCMCIA cards. They kind of died out, so it was definitely a big help for us,” explained Project Manager Randy Glover from Fredon Corp.

 

CNC floppy disks replaced by DNC hardware

Floppy drives are no longer needed to transfer CNC programs from desktop or laptop computers to CNC equipment, as today’s DNC hardware devices streamline the process.

However, beneath the surface of their convenience lies significant risk, especially when these devices are installed incorrectly or without adequate consideration for safety, network security and environmental compatibility. Improper DNC hardware installation isn’t just a maintenance issue; it can create serious safety hazards, compromise your network and lead to avoidable downtime.

Leveraging LAN Infrastructure for DNC Program Transfers

Ethernet-to-CNC devices offer DNC file transfer convenience for aged CNC machines that were built with floppy drives and still have an RS232 serial port to leverage Ethernet connectivity. They allow operators to upload or download G-code programs and standardize using network cables to all CNCs. But for manufacturers on a budget, it can be tempting to purchase low-cost devices on e-retailers and platforms like Amazon or eBay. The affordability of these options can be negated by the lack of compatibility or guidance to connect drivers, the specific controller and the DNC software itself. That’s where the risks start, as you or other team members attempt – rather blindly – to install inexpensive devices on your capital equipment.

 

Danger #1: Electrical Hazards, Operator Safety and Machine Damage

Improperly installed or low-quality CNC program transfer devices can cause short circuits, voltage surges, or ground loop issues, particularly when connected to older CNC controllers. And when cabling isn’t secured or properly integrated with standard safety procedures, there are added trip hazards, accidental yanks on live connections and entanglement with moving parts that are more than inconvenient – they are real safety threats that can result in injury or even death.

 

According to the U.S. Bureau of Labor Statistics (BLS), over 15% of workplace fatalities in 2022 were related to contact with equipment or electrical exposure. Yet many installations still run cables without shielding, strain relief or consideration for clearance

CNC machine maintenance work

Over 15% of workplace fatalities in 2022 were related to contact with equipment or electrical exposure, reveals the BLS, yet self-installed hardware devices still run cables without shielding, strain relief or consideration for clearance during machine cleaning.

during machine operation or cleaning. Then when an issue occurs, as Asian cabling provider JJ-LAPP describes, “in a tangle of unlabeled wires, your engineers have to trace that mess by hand. It’s a slow, frustrating process that can take way longer and lead to more mistakes. What’s worse, when you stuff cable trays too full, you kill the airflow. The cables overheat, which wastes energy and cooks the insulation, making them fail even faster.”

 

In a worst-case scenario of a poorly grounded USB adapter, unintended voltage spikes can be distributed to the CNC’s control board to not only fry serial ports or controller cards, but produce unexpected machine behavior, like motors jerking or stopping, and void machine warranties. The result of such spikes can lead to unexpected machine downtime, repairs and production schedule impacts. This can be a costly and frustrating outcome in the quest to “save” a few dollars with a cheap purchase and a Do-It-Yourself (DIY) installation, rather than partner with a professional manufacturing integrator, like Shop Floor Automations, and their skilled technicians.

 

Improper DNC hardware installation isn’t just a maintenance issue; it can create serious safety hazards, compromise your network and lead to avoidable downtime.

 

Up Next in Part 2: We’ll explore two additional threats: cybersecurity vulnerabilities and avoidable downtime caused by misconfiguration and oversight. You’ll also learn how to protect your team and productivity by treating DNC hardware as a strategic investment – not a DIY shortcut.

Aging Equipment for USB Upgrade
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CNCs That Are Not Yet Ready to Retire

Lengthen Useful Life with CNC USB Upgrades

You have a machine that is 30+ years old. It’s been there since the early days, long before Industry 4.0 was a buzzword and before wireless file transfer was even imaginable. It may be even going by the affectionate nickname of “Trusty.”

Despite its age, the equipment runs like a dream. Its spindles are still tight, axes still accurate within a few microns and its rugged build could chew through titanium like butter. Operators swear by its consistency. “It just knows what to do,” one would say. “Never crashes, never fusses.”

But there’s a catch. And it’s a costly one.

The machine’s control system, still original, can only receive CNC programs via two obsolete methods: a floppy disk drive and a Type I PCMCIA card slot. In an age when everything else on the shop floor has moved to USB, Ethernet or RS232 serial transfer, Trusty’s data interface is like a rotary phone in a world of smartphones.

PCMCIA Cards for USB Upgrade

The Bottleneck Begins

Every time a new G-code program needs to be loaded – be it a customer revision, toolpath tweak or entirely new part setup – one of the operators has to break from their routine to hunt down one of the two working 3.5″ floppy disks still in circulation. They probably guard those floppies like gold; one might be labeled “A-Shift Only” in Sharpie.

File sizes have to be trimmed meticulously. Programs have to be split into segments due to the 1.44MB limit. Worse still, perhaps the old laptop that supports the PCMCIA cards only works when plugged into a wall and booted in Safe Mode. You’re constantly worried that it will blue-screen in the middle of a critical job for an already-dissatisfied customer. The resulting delay could push an entire shift back, cause an overnight rush and lead to missed delivery windows. The warnings are clear: the machine isn’t failing mechanically, but it is failing logistically.

Good Machine Health Can Still Be Costly

Even if the machine can still “run well,” the time lost in file prep, operator retraining and manual transfers adds up. Even one mistake in file versioning – say, loading the wrong program because the floppy labels have rubbed off – means scrapping parts, rework or worse, customer complaints or attrition.

Machine Maintenance Work

Then there’s compliance. Traceability and control of removable media may be a major priority, particularly for manufacturers with Federal Contract Information (FCI), yet the tracking of file changes and revisions on a machine that relies on physical media is like trying to manage ERP through Post-it® Notes.

If these challenges sound eerily familiar, you’re among peers. But replacing your aging CNC equipment just to modernize data communication is rarely feasible for most operations. IndustryWeek published this shared opinion from one operations manager at a Midwestern automotive components plant: “We can’t justify scrapping equipment that still produces quality parts just because it lacks connectivity.” Instead, many are choosing to retrofit their legacy equipment – with tangible results.

Retrofitting for Longevity

The process of upgrading floppy drives and PCMCIA cards on older CNC machines can be surprisingly simple, that is, with the right hardware and manufacturing integrator. Shop Floor Automations (SFA), which specializes in delivering machine connectivity through a full suite of hardware and software solutions, refers customers to its USB Connect device to improve obsolete CNC file program transfer processes without retiring the asset. “It’s a ruggedized, plug-and-play unit that lets you load and save programs via USB just like you would on newer machines. You install it on the CNC and connect it to your machine’s RS-232 port, insert a USB flash drive containing your programs and send the file directly into the CNC control. There’s no software setup, no tweaking parameters. It behaves exactly like a serial communication tool, only far faster and easier to use,” explains Greg Mercurio, president of SFA.

These benefits make CNC USB upgrade retrofits increasingly attractive, but Mercurio advises a careful connectivity approach. “Choosing the wrong device or the wrong partner can quickly turn productivity or efficiency issues into unexpected downtime, safety or security issues. Cutting costs and attempting implementations without a well-crafted plan or experienced installer isn’t worth the risk,” says Mercurio.

A New Lease on Machine Life

Programs can now be sent directly from your shop’s programming workstation to Trusty and other older CNC machines, removing the need for floppies, patch cables or ancient laptops. The operator loads programs as if they used a removable USB thumb drive, but without all the marching back and forth between the programming office and CNC.

With this CNC USB upgrade device in place, operators can be empowered to focus on quality parts, not workarounds. Engineering can feel confident in a more streamlined CNC program transfer process. IT can rest easy with full awareness of this process, as well as the roles and responsibilities that result in a compliant and secure course of action. And long-standing equipment, like Trusty, can still run just as well, only now, with the tools to keep pace with the rest of the floor. Learn more about upgrading your existing machinery with expert assistance from SFA technicians by reaching out today.

CNC program transfers with Windows 10
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The Extended Lifeline of Windows 10 is a Ticking Clock for Manufacturers

Last month Nucor, North America’s largest steel producer, acknowledged a cybersecurity incident involving unauthorized third-party access to certain IT systems, reported Reuters. As a precaution, Nucor temporarily halted production at multiple facilities while forensic teams and external cybersecurity experts investigated the breach and worked to contain its impact. Nucor’s incident is just one example of how cyber threats exploit aging digital infrastructure – and for many manufacturers, that infrastructure often includes Windows 10. But with Windows 10 reaching end of support on October 14, 2025, there is a deeper risk for shops that continue to rely on aging CNC infrastructure.

Aging CNC infrastructures impact cybersecurity and operational efficiency

This year, manufacturers that don’t upgrade their Windows 10 machines risk missing critical OS-level security updates and losing compatibility with third-party solutions.

The New Reality of Windows 10 End of Life on CNCs

This year Windows 10 will no longer receive critical OS-level security updates. While support for Microsoft 365 apps on Windows 10 has been extended until October 2028, it’s far from a solution for the shop floor. It still means legacy CNC systems and other production technologies running on Windows 10 will become more vulnerable, not less. Compounding the risk, third-party vendors are already phasing out software support, while next-generation manufacturing platforms – from IIoT to real-time analytics – require compatibility with newer operating systems like Windows 11 and Server 2022. The gap between resilient, future-ready IT strategies and older shop floor systems is widening. This blog post explores what manufacturers can, and must, do to close that gap before it spreads into a serious operational liability.

The USB Epidemic: When Compliance and Productivity Collide

For many manufacturers still operating CNC equipment running on Windows 2000, XP or early versions of Windows 10, network segmentation or USB-based file transfers have become the go-to workaround for such outdated systems. However, this tactic is increasingly risky.

CNC program transfers with Windows 10

Running USB-based CNC file transfers have become the go-to workaround using Windows 10 and other outdated systems. However, this tactic is increasingly risky, exposing manufacturers to ransomware events, CMMC noncompliance and operational inefficiencies.

According to Honeywell’s 2022 USB Threat Report, “52% of threats are specifically designed to utilize USB removable devices,” with the vast majority of those threats able to disrupt industrial systems. Pair these threat actors with unsupported software, says Virgina Tech associate professor Lee Vinsel in a recent BBC article, and “there are all kinds of opportunities for failure here, especially when…companies stop supporting old software. Cybersecurity is a huge worry around this issue.” The Department of Defense well understands this concern. Its Cybersecurity Maturity Model Certification (CMMC) 2.0 framework prohibits unmonitored file transfers and insecure endpoints – meaning non-compliance can result in disqualification from federal contracts.

Operational inefficiencies further intensify the risk. Poor CNC program version control and manual CNC program transfers can cost production hours and potentially lower quality output as a result of incorrect or outdated G-code files being loaded at the machine.

Closing the Gap

Rather than investing millions in full machine replacements, many manufacturers are turning to modern Distributed Numerical Control (DNC) systems to serve as their secure industrial network. Solutions like Predator Secure DNC offer targeted upgrades that align with industry compliance frameworks and cyber-hardening strategies. IT and operational leaders can isolate legacy equipment from domain threats, centralize logging across mixed-machine environments, like Fanuc, Okuma, Mazak and others, and meet NIST SP 800-171 encryption standards via FIPS 140-2 validated cryptography.

The Cost of Complacency

Doing nothing may be the most expensive option. The global average cost of a data breach soared to 4.88M, the highest total ever, according to a 2024 IBM report.

For a temporary and limited reprieve, Microsoft offers an Extended Security Updates (ESU) for Windows 10 that starts at $61 per device Year One, with pricing doubling every consecutive year for a maximum of three years after the end of support for Windows 10. Even so, there is no extended Microsoft ESU option after this time period.

Plotting Your Path

To mitigate the risk of your manufacturing operations, IT and operations should take the following steps to prepare for the end of Windows 10 support:

Windows End of Life on CNCs

  1. Conduct a CNC Operating System (OS) and network audit before Q3 2025, identifying all legacy systems still running Windows 10 or earlier.
  2. Prioritize upgrades for machines processing sensitive IP or DoD-controlled projects.
  3. Implement secure DNC options along with Microsoft’s ESU to support phased migrations and DNC retrofits while maintaining compliance and uptime.

Maximizing Grace Periods

Microsoft’s 365 extension for Windows 10 is not a pardon, it’s simply a grace period. Manufacturers who fail to act may find themselves next in line for a costly ransomware event or compliance failure.

Manufacturing integrator Shop Floor Automations (SFA) has worked with hundreds of manufacturers to navigate such transitions securely and efficiently. The path to a resilient, connected shop floor doesn’t begin with rip-and-replace – it starts with informed decisions and trusted partners.

To receive technical guidance for your manufacturing operations, contact the experts at SFA now.

Prep tips to ensure your onsite manufacturing integrator service doesn't cause delays.

How to Avoid Costly Delays During Onsite Manufacturing Integrator Service

Save Thousands with Quick Installations for Faster ROI

 

Picture this: The manufacturing integration technician arrives, ready to install your long-awaited machine monitoring, PDM software or DNC software. But within the first 10 minutes, there’s a problem—there’s no login credentials available and your IT staff is occupied with another project. You put in a support ticket to your Managed Services Provider (MSP). The technician waits. Then waits some more. You also learn the IP address that was previously provided is not configured for the proper VLAN. Before you know it, the billable hours are stacking up.

Sound familiar? Hopefully not.

Implementing shop floor software and hardware solutions, especially as part of a connectivity and automation strategy in partnership with your trusted manufacturing integrator, can transform your shop floor’s efficiency—but only if the setup goes smoothly. Every unnecessary holdup adds extra costs of delay, eating into your budget, productivity and ROI realization.

The Costs of Poor Planning

If the technician has to wait for network access, firewall changes or machine availability, you’re paying them to stand around. Your internal team may need to drop other priorities to troubleshoot issues, creating a ripple effect on other projects and avoidable stress and frustration. If delays force a technician to leave and return later, additional travel time and service charges may apply, and tight schedules may push installations even further out. A longer implementation of your software defers its benefits, like potential improvements to efficiency, Overall Equipment Effectiveness (OEE) and downtime, and produces hardware and software licensing waste. And if your machines were taken offline in anticipation of the installation, delays extend unplanned downtime – potentially impacting delivery commitments and disrupting work among operators and supervisors. Each day of delay also leaves you susceptible to falling behind competitors who are busy optimizing their shop floor performance.

Scrap that vision of last-minute scrambling.

Instead, let’s see how you can maximize the installation process and avoid wasting billable service hours with these four practical steps. Your future self (and your CFO) will thank you.

  1. IT & Network Preparation. Start out by installing any required software onto a dedicated PC/server that meets the system’s requirements. Ensure administrative permissions are set for installation and test user logins and any necessary database connections. Apply all Windows updates/patches and have your PC on your network. Open necessary ports for firewall and network access and assign static IP addresses for all relevant CNC machines. Verify Internet and internal network access; if a proxy or VPN is needed, configure it in advance.

💡 Pro Tip: Running a quick pre-installation network check can prevent hours of billable troubleshooting.

  1. Facility & Equipment Access. Prior to your technical installation, secure machine access by powering on all CNCs and granting the technician permissions, like the ability to restart machines, as required. If an escort or safety orientation is mandatory, arrange or complete it before the technician arrives. Prepare the technician for your specific manufacturing environment by confirming any PPE requirements beyond steel-toe shoes and safety glasses. Ask your manufacturing integrator about standard service hours to ensure that overtime demands are minimized. Be sure to have essential personnel, including staff in IT, Engineering and Maintenance, on standby to assist immediately if needed.

💡 Pro Tip: Every minute a technician waits for access or approvals is wasted.

  1. Machine-Specific Configuration. Validate that data collection setup is ready and cabling and connectivity is set. Confirm network drops or Wi-Fi credentials are valid and tested. Keep this information on hand for the technician’s reference.

💡 Pro Tip: If a new installation is involved, lean on personnel familiar with the machine controller and operation to assist with machine parameter changes if needed.

  1. Final Check-In & Testing. Confirm all pre-installation steps with your manufacturing integrator. Double-check that hardware, adapters and licensing is ready to go. Lastly, validate the expected data collection method, machine connectivity to the server and openness of required ports and firewall rules.

💡 Pro Tip: A quick pre-installation test call with tech support can prevent major headaches and productivity losses on installation day.

Now picture this: The manufacturing integration technician arrives to implement your modern machine monitoring, PDM or DNC software. Before the technician’s arrival, your IT team has already confirmed network connectivity, ensuring IPs are valid and firewall settings are configured. You have software pre-installed, permissions granted and a pre-check conducted with your technician.

Busy manufacturer benefitting from its shop floor software and hardware implementation.

With the right manufacturing integrator and the right prep, your team can start realizing ROI from your shop floor software and hardware quickly, efficiently and effectively.

Once onsite, the technician gets straight to work, efficiently installing and configuring the software. Within minutes, your team is seamlessly accessing real-time data streaming from the machines, organizing CNC programs with revision control or transferring CNC files. Machine uptime is restored and personnel can continue about their day. Instead of frustration, the project ends with a successful implementation and a future-ready manufacturing floor.

Preparation is the Key to Success

A poorly prepared installation of shop floor software and hardware can easily cost thousands of dollars in billable hours, downtime, lost productivity and delayed ROI. Plan ahead with the manufacturing integrator experts at Shop Floor Automations to experience a smooth install, faster operational benefits and lower total costs – contact SFA today.

Equipment monitoring software for maintenance
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The Dilemma of Do-It-Yourself Equipment Monitoring Software

Downtime – and the response time to it – continues to plague manufacturers across the United States. A 2022 Siemens report revealed that a typical large plant “still loses 25 hours a month to unplanned downtime.” They estimate the cost of an hour of downtime to be $500,000 for oil and gas companies, which makes downtime quickly cost millions.

As a result, teams are responding by gathering internal technical requirements, evaluating off-the-shelf machine monitoring solutions and attempting trial implementations. Top machine monitoring solutions will capture data from new and aged CNC equipment and deliver trends and reports using configurable dashboards via modern communication tools, like text and Microsoft Teams, to help you pinpoint production bottlenecks and machine condition degradation for improved Overall Equipment Effectiveness (OEE), quality control and profitability.

CNC machine monitoring for downtime monitoring

But there are hundreds of available equipment monitoring software solutions today, ranging from Predator Software to Scytec DataXchange and beyond, and the equipment monitoring market itself is projected to reach 220.92 million USD by 2031. This makes the vendor decision-making process all the more onerous and lengthier, particularly for time and labor-constrained companies. Some manufacturers are instead taking on a Do-It-Yourself (DIY) approach by assembling internal and/or outsourced developers, collaborating with various departments and rolling out a custom solution. There’s an attraction to this path, but is it truly the right way toward achieving more uptime, better operator performance and greater profits?

If you’re considering or already headed in this direction, you very well may consider the positive and negative aspects of DIY equipment monitoring development to fully validate your decision. As a manufacturing integrator experienced in helping manufacturers search, select and implement the ideal machine monitoring software solution for your business, the experts at Shop Floor Automations have compiled a comprehensive list to aid your research below. We welcome your comments on other advantages and disadvantages that factor into your own machine monitoring evaluation.

The Pros of DIY Equipment Monitoring Software Development

  • Potentially less upfront cost. When your teams develop equipment monitoring software in-house, you’re not likely to incur the recurring software subscription or license fees demanded by software vendors. Software subscription revenues are anticipated to grow by a CAGR of 16.6% reports EY, as enterprise technology companies continue to shift away from a perpetual software license model. You also have the benefit of leveraging existing programmable logic controllers (PLCs) without upfront costs for hardware and training to program it.
  • Built your way. Machine monitoring software designed for your business can be customized to accommodate your specific business processes, equipment types, locations, unique terminology and standards, integrations and more. You’re not forced to adapt to the user interface, limitations and future development of a commercial application geared for a mass of users.
  • Vendor neutral. A DIY equipment monitoring project allows you to be in control, deciding who is involved and how the system and data is maintained, supported, secured and located. Conversely, a machine monitoring software provider will often dictate the supporting partners and underlying ecosystem available with the solution – which can require data hosted by their third-party provider.
  • Fringe benefits of familiarity. When you’re able to dedicate your resources to your own project, you can command your own timetable, training program and the coordination of subject matter experts. There’s less of an educational barrier, too, as teams should be familiar with the corporate nomenclature, key personnel and strategic priorities. The purchase of a commercial application like equipment monitoring software, however, means you are beholden to the skills, bandwidth, language and processes of the technology provider and the demands of their existing customer base.

The Cons of DIY Equipment Monitoring Software Development

  • Susceptibility to higher Total Cost of Ownership (TCO) and other impacts. The TCO of your DIY equipment monitoring system goes beyond just IT salaries; often the continued energy costs, hardware, security, training, networking, backup, testing and more will make this project far more expensive than commercial applications. Your custom software would also likely be impacted significantly by change: budgetary constraints, shifts in strategic objectives and corporate systems and policies, personnel movements and other factors. As a dedicated technology business to many users, the commercial developer tends to better absorb and rebound from events like employee attrition and economic impacts.
  • Competing departmental prioritiesLess emphasis on contingency and continuity. As an internal project, DIY machine monitoring software can be more prone to decreased attention over time, particularly if the project champion has left for another opportunity or moved to another department. The software and its related documentation and training programs, then, are less likely to stay current or remain relevant as new technology and security protocols are introduced to the business, new machinery is acquired and older machinery is retired or networks are upgraded. In this age of rapid change, software that sits doesn’t help a bit.
  • Forfeiting best practices. Custom software, such as DIY machine monitoring, inherently lacks the benefits that come from applying industry best practices, including data trends across wide swaths of users and equipment types, new AI developments, the latest security standards and other technological advancements that require research, resources and large, varied datasets. The core competency of software vendors often affords them greater focus, expertise, budgets, data access and more to help customers refine their business processes through proven functionality.
  • Shouldering the burden of ongoing maintenance and improvements. New requests for features require manual updates to hardware when working with DIY machine monitoring software. Maintenance technicians, for example, have to update the PLC hardware to capture each additional signal desired by internal management. This step may need to be replicated for each machine tool, which can be time-consuming and requires additional documentation to capture every change. Commercial machine monitoring, on the other hand, enables configuration via a web browser without the need to physically walk to the equipment.

In this age of rapid change, software that sits doesn’t help a bit.

Custom machine monitoring applications tend to be rigid in design, requiring a multitude of support tickets to increase flexibility as users engage with the software over months and years. Commercial equipment monitoring solution providers, alternatively, configure the System Resource Controller (SRC) and deploy changes easily. Their solutions tend to be out-of-the-box configurable for user control of reports, charts, and dashboards based on your machine brands. Software developers also have streamlined processes in place to accommodate continued development schedules and software enhancement and integration requests.

A DIY approach to equipment monitoring software can appear practical, especially for manufacturers with in-house IT development. But it’s important to look beyond upfront factors to include the entire scope of such a project, so that your TCO encompasses all opportunity costs, barriers necessary to overcome and anticipated internal and external changes that will impact short- and long-term development. After all, a deviation from core competency can be a costly mistake for manufacturers already reeling from downtime and production loss.

Ransomware on CNC Machines
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Building Resistance into Aged CNC Machines

How CNC program transfers can overcome the vulnerabilities of SMB1 for greater security and efficiency

It took mere hours. In May of 2017, a devastating ransomware cryptoworm called WannaCry impacted more than 200,000 computers across 150 countries, ultimately amassing over $4 billion in damages. Only months later, a variation of this worm spread to 10,000 machines in Apple’s single supplier of SoC components for iPads and iPhones, causing a production stoppage for a full day and shipment delays among its major tech customer base. The original worm was halted, but IT services management company Cloudflare asserts that WannaCry attacks continue today.

Ransomware on CNC Machines

The ransomware cryptoworm WannaCry notably affected TSMC, which manufactures processors and other silicon chips for major technology companies such as Qualcomm, AMD and Apple, due to a Windows SMB1 server vulnerability.

Starting with SMB1

What happened to the National Health Service (NHS), FedEx, Taiwan Semiconductor Manufacturing Company (TSMC) and so many others? The WannaCry worm exploited “vulnerabilities in the Windows SMB v1 server to remotely compromise systems, encrypt files and spread to other hosts,” explains a fact sheet from the National Cybersecurity and Communications Integration Center (NCCIC). While patches have since been issued by Microsoft, the software company admits there are still instances in which manufacturers may need to run SMB1:

    1. Your company is running XP or Windows Server 2003 under a custom support agreement
    2. You have old management software that demands admins browse via the “network,” also known as the “network neighborhood” master browser list
    3. You run old multi-function printers with antiquated firmware in order to “scan to share”

For manufacturers experiencing such cases, there are workarounds. SMB1 could be disabled on every system connected to the network, recommends the NCCIC. You can block port 445 (Samba). You can verify that there isn’t any unexpected SMB1 network traffic. You can isolate vulnerable embedded systems. But these options may not necessarily be viable for efficient and protected CNC file transfers among aged equipment.

Transfer CNC Programs on SMB1 Machines

Manufacturers can struggle to disable SMB1 on every machine and still transfer CNC programs efficiently, effectively and securely.

Simplifying Network Setups

An alternate route is to simplify network setups altogether. A modern DNC software, like Predator Secure DNC, enables you to remove Windows shares, corporate domains, workgroups, homegroups, Microsoft SMB, CFS, FTP, DNS, WINS, NETBUI and IPX/SPX within shop floor VLANs, WANs or subnets for DNC or file transfers. This can be especially useful for manufacturers running older CNC equipment with Windows-based controls that lack compatibility with newer operating systems. It can also alleviate the need for system upgrades and service packs to maintain the older versions of Windows.

The original WannaCry worm was halted, but Cloudflare asserts that WannaCry attacks continue today.

In other cases, controllers like Haas classic controllers can be upgraded to another SMB version by contacting the machine tool builder or segmenting the network to address CNC machines that are not upgradable or do not run a Windows operating system. The point is, regardless of your SMB1-dependent machinery environment, you can reduce your ransomware risk while gaining the latest benefits in efficiency and productivity.

An experienced manufacturing integrator possesses the technical expertise to properly assess, assign and execute custom solutions for your company. Contact Shop Floor Automations to understand your full scope of SMB1 options today.

Scrap material in manufacturing - Shop Floor Automations
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Revise Your Revisions: Scrapping the Rework from Poor CNC Production Documentation

Imagine this: as a manufacturer, one of your engineers or CNC programmers has finally completed a product design for a part worth $75,000. They add the files to a USB thumb drive and run it out to the shop floor to upload the design and work instructions for the second shift. Success, he or she thinks. However, one of your team members made a last-minute change to the files without your knowledge. You won’t find out until the prototype is rejected by the customer, scrapping the part and costing your company thousands of dollars, even more time and effort, further project delays, interdepartmental frustration and a dissatisfied customer. Yikes.

Ideal PDM software ties engineering designs, CNC programs and production documentation for full revision control

In reality, manufacturers today have far greater ability to prevent a scenario like this from occurring in the first place. Modern production data management or product data management (PDM) software solutions are specifically designed to manage your manufacturing documentation, like CNC programs, CMM programs, machine offsets, Standard Operating Procedures (SOPs) and Material Safety Data Sheets (MSDS), to reduce inaccuracies, improve productivity, security and efficiency and speed up time to market. The revision control features of a well-designed PDM, such as Predator PDM, can allow for revisions per vault item, not per file, allowing you to condense the number of files it takes to run your business. New revisions or status changes are validated once-a-minute on every shop floor PC, and the correct program and work instructions may be selected from a pick list tied with the job scheduled in your ERP or MES system – all features to ensure the right CNC production documentation is sent to the right job at the right time.

Proper PDM software aids the CNC program and documentation process on the shop floor for less waste, faster time to market, increased productivity and more.

The use of Windows folders and other alternatives to fulfill regulated traceability requirements often fall short of meeting compliance standards.

Compliance Tracking for CNC Production Documentation

“Manufacturers and their industry partners are becoming greater generators and consumers of data output from their operations, particularly as automation increases,” wrote the National Institute of Standards and Technology (NIST) in late 2023. As regulatory bodies, such as the Food & Drug Administration (FDA), Department of Defense (DoD), and the Federal Aviation Administration (FAA) seek to control this data collection and consumption movement, manufacturers are responsible for tracking, restricting and proving the path of all production documentation. Applying traditional means, like pen and paper, text files or Windows folders, to meet the latest traceability requirements lack the revision control, visibility and reliability to fulfill such mandates. Even USB thumb drive usage can be significantly limited or prohibited altogether in order to achieve compliance. With so much regulation and new technology available now, how does a manufacturer find and implement an optimal PDM solution?

A partnership with a manufacturing integrator with experience in your industry – be it aerospace, defense, oil and gas, medical device and pharmaceuticals or another industrial sector – and a broad software and hardware portfolio can help you better navigate options to institute effective and compliant processes to deliver profitable products. Contact a manufacturing expert at Shop Floor Automations to help reduce time to market, decrease waste and enhance the security of your CNC production documentation by visiting shopfloorautomations.com now.