FEATURE Smart factories/software
MACHINE CONNECTIVITY DRIVES EFFICIENCY
Here, Greg Cocks, Senior Manager of European Sales Engineering at machine tool manufacturer Mazak, explains how digital transformation is being driven by the need for increased efficiency, quality control and competitiveness
C
ompanies that connect their machines and access real time data typically increase productivity by 10%, and with additional in-depth analysis, can further increase production efficiency up to 20%. The number of connected devices increased from 15.9 billion in 2023 to 18.8 billion by the end of 2024 – showing growth of 13%. Meanwhile investments in technology accounted for almost a third of manufacturers’ budgets indicating the growing adoption of connectivity systems. Let’s begin by looking at the challenges manufacturers face daily. Unplanned machine down time can have a crippling effect on company performance and knock-on impacts across the supply chain. A report by Deloitte (2024), says unplanned downtime can cost manufacturers up to $50 billion annually because of lost production, missed deliveries and unplanned maintenance costs.
Having the ability to monitor data
from operations, assets and processes in real time enables manufacturers to assess all aspects of their production lines and quickly identify issues before machine failure. To illustrate, the latest McKinsey report claims that using real time data in this way can reduce downtime by 30%. While the reduction in downtime is a key factor, the increased adoption of real time connectivity systems is being driven by the urgent need for enhanced efficiency, improved quality control, and a need to remain ahead of the competition. The analysis of real-time data from sensors and equipment also enables manufacturers to adopt a predictive approach to maintenance so they can
20 October 2025 | Automation
plan ahead and reduce downtime – a major contributor to manufacturing financial losses – with one report stating large manufacturers lose around $1 trillion a year due to machine failure.
Real-time data systems, such as the iCONNECT Machine2Machine connectivity platform from Mazak, gives manufacturers the ability to optimise machine utilisation. Monitoring the performance of multiple machines allows manufacturers to identify bottlenecks and optimise schedules, leading to significant improvements in overall equipment performance.
Real time data analysis also enables faster detection of faults or quality issues with products coming off a production line. Another study shows how, after implementing an automated quality management platform, a company reduced rework by 30% and increased yield by over 5% in the first year. However, with increased connectivity comes concerns from organisations that connecting equipment creates a cyber security threat. This is why connectivity should be provided by machine tool builders such as Mazak, with the commercial strength to partner with leading Operational Technology (OT) security providers such as CISCO, ensuring compliance with regulations and, ultimately, protecting customers. Mazak’s connectivity platform has been developed to support manufacturers in two key areas. The first sees it acting as an information portal to provide a linear view of all assets. The second stage enables more in- depth data reporting and analysis so real time decisions can be made to address issues with individual assets or as a collective. Mazak, supported by partners Cisco and TeamViewer, has the capability to install and
activate a highly secure data connection on all machines, mitigating the security threats mentioned earlier. They also ensure a consistent level of real time data which can be accessible from an intuitive web portal or as a connection to common business analytics tool such as Microsoft Power BI.
This web portal also enables remote support of a customer’s machine tool and gives the customer the ability to back-up machine settings and programmes to secure cloud storage. The partnership with CISCO is also helping to bridge the gap between productivity and sustainability by optimising machine utilisation and working towards carbon neutrality.
Manufacturers are increasingly acknowledging the positive impact of digitalisation, evidenced through the growth in sign-ups of iCONNECT, with almost 3000 customers from 80 companies using the platform and more than 240 machines being monitored. Systems such as this enable manufacturers to monitor, in real time, the utilisation of their machines on the shop floor which has a positive impact on production, leading to increased profits.
As the sector continues to evolve, those embracing digital transformation will be better positioned to meet the challenges of an increasingly competitive market. Companies leveraging these technologies report significant commercial benefits, including a 30% reduction in downtime and a 12% increase in productivity. Tools like Mazak’s iCONNECT platform gives manufacturers the capacity to create more agile, efficient and responsive operations – ultimately driving innovation and growth in the industry.
Mazak
www.mazak.com/uk-en/
automationmagazine.co.uk
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