Your Milling Machines deserve a Digital Upgrade – without any new investment
Are you unknowingly losing time and resources in your milling operations?
Whether from Hermle, DMG MORI, KUNZMANN, EMCO, POS, or others — many manufacturing companies in Germany still rely on reliable but often non-transparent milling machines from different manufacturers and generations. The machines are running — but it often remains unclear where time is being lost, how productive they actually are, or how much energy they consume.
Especially with older milling machines, the data foundation required for informed decisions is often missing. Different control systems, machine ages, or machine types make it appear difficult to capture, all machines within one system — but this is exactly where Novo AI comes in.
With the AI sensor system and the WatchMen platform, we make milling machines visible — in real time, independent of manufacturer, and without interfering with the machine control system. Our solution captures machine states, cycles, runtimes, and downtime directly at the machine — from Hermle machining centers and DMG MORI milling machines to KUNZMANN machine tools. Even machines that are more than 30 years old can be digitally upgraded this way — simply, quickly, and with immediate benefits.
Your machines do not need to be new — they simply need to become measurably better.
No matter the machine age, no matter the manufacturer — we retrofit your milling machines
Do you use milling machines from DMG MORI, Mazak, Hermle, HAAS, Okuma, Chiron, Makino, Hurco, Deckel Maho, Heller, Bridgeport, Kearney & Trecker, Schaublin, Gildemeister, Matsuura, Doosan, Cincinnati, Aciera, Emco, Hwacheon, Spinner, Colchester, Mikron, Fehlmann, Lagun, Hartford, Fexac, Weiler, Maho, Kondia, Sigma, Kitamura, Leadwell, ZPS, Toshiba, TOS, MTEor even discontinued brands such as Deckel, Rambaudi, or Giddings & Lewis?
Perhaps even a mixed environment with different machine ages, control systems, or machine sizes? No problem. With Novo AI, you can retrofit all these milling machines simply, safely, and quickly — without expensive rebuilds and without interfering with the machine control system.
Our AI sensors are mounted externally on the machine — independent of machine type, condition, or year of manufacture. They capture high-resolution vibrations, acoustic data, and energy consumption directly at the machine and transfer this data in real time to our central WatchMen platform — or, if desired, directly into your existing ERP system.
Whether it is a 5-axis machining center from Hermle, a DMG MORI DMC series machine, a robust production machine from HAAS, or a refurbished Deckel machining center from the 1990s:
We make every machine visible and comparable — across manufacturers, retroactively, and completely without requiring IT expertise on your side.
Your machine park becomes a digital manufacturing system — standardized, efficient, and future-proof.
Fast & simple retrofitting — even without an IT team
Many manufacturing companies face the same challenge:
“I do not have an IT department and my employees are not digital experts — how is this supposed to work?”
The answer: With Novo AI, that is not a problem.
Our AI sensor can be installed within 15 minutes per milling machine — completely without interfering with the machine control system and without requiring specialized knowledge.
All you need is:
- A power connection
- A Wi-Fi connection or LAN port
The sensor is simply mounted externally on the machine — no opening of the milling machine, no connection to the control system, no risk to warranties.
After installation, it automatically transfers all relevant data to the central WatchMen platform, where you can see in real time:
What your milling machines are currently doing — transparent, live, and reliable.
Captured machine states include, for example:
- Productive (chips are running, parts are being milled)
- Setup process (tool changes, setting zero points, changing clamping devices)
- Idle running (machine ready, but no active cycle)
- Downtime (unplanned, e.g. due to alarms or workpiece defects)
- Planned stop (breaks, shift changes)
- Maintenance or servicing
- Run-down time / run-out phase
- Setup mode / test operation
- Energy standby / standby mode
Whether you operate a DMG MORI DMC 1035 from 2010, a used Hermle C40, or a modern 5-axis milling machine from Mazak — the retrofit process always remains equally simple.
And if something does not work as expected? We are here for you.
Our team supports you during setup — on-site or through remote support.
You and your team do not need any technical experience.
The solution works — even if you have previously worked with paper and Excel.
✅ No programming
✅ No IT configuration
✅ No risk
Simply get started — and instantly see what your milling machines are truly capable of.
Direct integration into your ERP system — for seamless workflows
Do you already work with an ERP system such as SAP, proALPHA, ABAS, Microsoft Dynamics, PSIpenta, Infor, Oxaion, or an industry-specific manufacturing solution?
Perfect — because that is exactly where your machine data from the milling shop should end up.
With Novo AI, connecting to your ERP system is simple and efficient. Our WatchMen platform was developed from the very beginning to be open, modular, and fully compatible:
✅ Integration via API or standardized ERP connectors
✅ Automatic transfer of your production, machine state, and energy data
✅ Compatible with existing infrastructures — without complicated adjustments
✅ Optional: Direct collaboration with your ERP provider or IT system integrator
As soon as our AI sensor is installed on your milling machines, it transfers all relevant information to WatchMen in real time — from spindle runtimes and cycle durations to downtime reasons and setup phases.
If desired, this data can be made directly available inside your ERP system, for example for:
- Order and production feedback
- Productivity analysis on machine or shift level
- Post-calculation and controlling
- Energy or CO₂ reports
- Live dashboards for management, planning, or operations leadership
You decide which data flows where, at what level of detail, and with what frequency.
We advise you individually and implement the ERP integration together with your team or external partners — practical and aligned with your existing IT infrastructure.
Building trust — machines in focus, people at the center
Digital transparency is the foundation of every modern manufacturing environment — but it also raises questions:
“What exactly is being captured? Who can see the data? And is this about control?”
At Novo AI, one thing is at the center:
improving your machine performance and production processes — not monitoring people.
Our AI sensor delivers objective data about spindle runtimes, cycle times, energy consumption, cycle deviations, and more — without changing the control system or interfering with the machine itself.
Many employees working on milling machines rely on experience, routine, and intuition.
That works — until something gets out of control: a machine stops, cycle times break down, or a part is rejected.
In those moments, the critical information needed to react quickly and correctly is often missing.
This is exactly where WatchMen helps.
Our platform shows in real time what is happening in the milling shop — transparent, understandable, and straight to the point.
This allows employees on the shopfloor to:
- identify problems faster
- understand why a machine is running idle
- see how efficiently parts are currently being manufactured
- proactively adapt their way of working instead of only reacting afterward
Managers, in turn, receive a tool that enables them to:
- analyze processes objectively
- make decisions based on facts
- support teams more effectively
- develop improvement ideas together with employees
👉 The data shows causes instead of symptoms
👉 It makes relationships visible that previously remained hidden
👉 It helps ask the right questions — instead of searching for someone to blame
And that is exactly what creates trust.
Because when everyone in the team understands how their work contributes to overall performance, a new and stronger collaboration emerges — based on facts instead of assumptions.
The WatchMen platform reduces pressure instead of creating it.
It helps avoid downtime, increase productivity — and above all: make everyday work simpler and clearer.
Start now — without risk and with clear cost control
Getting started with digital machine transparency does not need to become a large-scale project. Quite the opposite: With Novo AI, you can start small and see results immediately — completely without major investment pressure.
Our solution is scalable step by step. That means:
You can start with just one milling machine — whether from Hermle, DMG MORI, KUNZMANN, or EMCO — and experience the effects live. Even with a single AI sensor, you gain valuable insights into runtimes, idle phases, and production cycles.
Your advantages when getting started:
Low entry costs through pilot projects
We offer starter packages specifically designed for testing individual machines — without long-term commitments and without risk.
Funding programs and support available
Together, we evaluate whether you can benefit from regional or national digitalization funding programs. We actively support you with the application process and project documentation.
Grow at your own pace
As soon as you see the benefits, you can expand the retrofit to additional machines at any time — with a clear cost structure and a coordinated rollout.
Most of our customers report concrete “aha moments” after just a few days: where energy is being lost, where cycle times slow down, or where simple adjustments create a major impact.
Getting started with data-driven manufacturing has never been this simple — or this secure.
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Productive Machine Time Gained
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Machine Idle Time Eliminated
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Less Energy Waste
Questions or interested in learning more? We’re happy to help.