The productive phase is the core value-creating stage of any machine. WatchMen automatically identifies this phase based on the machine’s characteristic vibration, energy consumption, and motion patterns. The system precisely distinguishes whether the machine is actively processing material or merely performing pre- or post-processing activities.
By accurately detecting this critical production phase, WatchMen generates reliable data on actual machine performance, cycle times, process stability, and the true output capability of the equipment. This makes it possible to see how much of the available machine time is genuinely spent on value-adding production — and where opportunities for improvement exist in day-to-day operations.
Setup processes such as tool changes, material loading, changeovers to other products, or setting up new programs regularly cause interruptions. WatchMen clearly identifies these activities based on recurring patterns and fully separates them from productive time.
This makes it transparent how long machines actually need for setup, how much setup times vary between operators, and where organizational or technical improvements are possible. Setup times are one of the largest hidden efficiency levers — and can now be measured objectively for the first time.
Idle time is the state in which the machine is switched on but remains unused. It can be caused by missing material, missing operator input, planning issues, or internal workflows. WatchMen makes these unproductive periods visible in real time and also shows how often and how long they occur.
This state is often one of the biggest OEE killers in manufacturing companies, but it usually remains hidden in day-to-day operations. Through precise detection, teams can derive concrete improvement measures, such as better work preparation, improved material logistics, or optimized operator allocation.
Downtime occurs due to faults, sensor errors, tool breakage, organizational issues, or a lack of process stability. WatchMen documents every downtime event with second-level accuracy, detects the underlying patterns, and separates them from regular idle time.
This transparency makes it possible to identify root causes in a targeted way and eliminate them systematically — often with a significant impact on overall equipment effectiveness and the reliability of the entire production process.
Planned stops include breaks, shift changes, cleaning activities, and organizational interruptions. WatchMen automatically detects these intervals and classifies them correctly.
This keeps the daily timeline consistent and prevents planned interruptions from being misinterpreted as unproductive time. As a result, planned-versus-actual performance can be assessed fairly, without distortions caused by scheduled interruptions.
WatchMen detects patterns that may indicate potential technical problems. Based on vibration, acoustic, and energy profiles, possible defects or increasing signs of wear can often be identified at an early stage.
The combination of anomaly detection and historical pattern analysis enables condition-based maintenance without additional sensor effort. This helps reduce unplanned failures, makes maintenance more predictable, and increases the technical reliability of the equipment.
WatchMen detects production cycles based on clear physical signatures — without any connection to the machine control system. Each cycle is counted, analyzed, and linked to the process timeline.
This creates:
Cycle detection works for single-stroke machines, takt-based processes, presses, and machining equipment, as well as for continuous production processes.
By precisely identifying the start and end of each production cycle, WatchMen determines reliable production counts. These figures are completely independent of the machine control system and are based solely on the machine’s actual physical activity.
This ensures that counted parts accurately reflect real production output — even on older machines or equipment without data interfaces or production documentation systems.
In extrusion, profile manufacturing, hose technology, and other continuous production processes, WatchMen automatically measures running meters without any intervention in the machine. The system detects changes in material flow, speed fluctuations, idle phases, and stops, and uses this information to calculate reliable production quantities.
This enables precise analysis of output performance, quality patterns, material efficiency, and speed trends.
WatchMen analyzes dynamic motion and process patterns and detects whether the machine is accelerating, slowing down, stagnating, or operating irregularly.
This information is used to assess process stability and helps companies understand whether machines are consistently operating within the optimal range or whether hidden efficiency losses are occurring.
The machine view provides a compact yet highly detailed overview of the most important daily performance indicators. Users can see:
This creates a complete diagnosis of each machine — objective, neutral, and accurate down to the second.
The signal timeline displays the machine-level process in multiple levels of resolution, providing both a high-level overview and detailed diagnostic capabilities:
This view replaces time-consuming manual troubleshooting and provides an objective, data-driven way to identify production issues.
The historical view reveals long-term trends that are often overlooked in day-to-day operations:
This view is essential for identifying structural issues and long-term improvement opportunities — not just isolated events from a single day.
WatchMen automatically separates shifts and enables objective comparisons across:
This makes differences between shifts transparent and measurable — without relying on subjective assessments or assumptions.
On the shopfloor tablet, operators can directly capture all relevant information and inputs:
The interface is deliberately reduced, clearly structured, and easy to use in any production environment.
Once operators work with personalized user assignments, evaluations can be created on an individual basis, including:
This turns the system into an objective tool for fair, data-driven performance evaluation and continuous improvement.
In the hall layout, teams can see at a glance:
This live transparency improves communication, accountability, and fast response in shift operations.
For management, lean teams, and controlling, central company-level KPIs are available, including:
This creates complete transparency across the entire production environment — down to the individual machine level.
The planner connects employees and machines with shifts and production orders. As a result, all analyses are automatically assigned to the correct context.
The result: clear responsibilities, reliable reporting, and improved production planning.
Tickets enable clear and transparent handling of disruptions, quality issues, maintenance tasks, and internal work items. No verbal handovers, no paper, no ambiguity — everything is traceable from “open” to “resolved.”
Machines are made comparable based on their key performance indicators:
This allows the team to immediately identify the best and worst performers.
The module shows:
Ideal for training, coaching, and employee development.
Leaderboards make performance visible across the organization:
This level of transparency encourages motivation, accountability, and a culture of continuous improvement.
Novo AI enables a fast entry into data-driven manufacturing—without an IT department or complex integration. With simple machine retrofitting using AI sensor, you gain transparency into runtime, energy consumption, and utilization, increase production output, and sustainably reduce energy costs.
With Novo AI, you make your machines Industry-4.0-ready: simply retrofit, capture machine data, and see in real time what your production is truly delivering.
According to VDMA, machine retrofitting is the most important step in transforming existing equipment toward Industry 4.0 and achieving sustainable efficiency gains.
Machine retrofitting is the fastest path to digital manufacturing. With Novo AI, you get a complete solution for machine data collection—simple, secure, and manufacturer-independent. Capture and analyze machine data to sustainably increase productivity, without costly PLC modifications or complex IT integration. Machine Retrofitting gives manufacturers a practical way to modernize existing equipment step by step, while keeping production stable and investment risk low.
Our AI sensors make your machines Industry-4.0-ready, delivering real-time production data, OEE analysis, and energy optimization. Start your retrofit project now and turn your production into a smart factory.
Further information on Industry 4.0 and retrofitting can be found on the Plattform Industry 4.0.
Our AI sensor can be installed in just 15 minutes per machine. No specialized expertise required.
Once installed, the sensor automatically transmits all relevant data to the WatchMen platform—giving you real-time visibility into what your press brake is doing, live and measurable.
Your machine park is diverse—different ages, control systems, and configurations? No problem. With Novo AI, any production machine can be retrofitted. The AI sensors are mounted externally, completely independent of brand, type, or year of manufacture—no modifications, no control-system access. Machine retrofitting makes this possible without replacing existing assets, turning mixed machine parks into connected, measurable production environments.
All machine data flows in real time into the WatchMen platform or, if desired, directly into your ERP system. This creates a fully data-driven, AI-powered production environment with transparency across downtime, idle time, and energy consumption.
The result: real-time production monitoring, predictive maintenance, machine performance optimization, and OEE analysis—across all machines, centrally managed, vendor-independent, and efficient.
Already using an ERP system like SAP, Microsoft Dynamics, or Infor? Perfect—because that’s exactly where your machine data belongs.
With Novo AI, connecting your machines—whether drilling machines, milling machines, or press brakes—to your ERP system is simple, secure, and efficient:
Novo AI integrates seamlessly into your ERP – without disrupting your IT.
Machine retrofitting goes beyond data collection: your machines deliver actionable real-time data for productivity, energy optimization, and full Industry-4.0 visibility.
...teams actively use the data every day.
They instantly see where problems occur, why machines are idle, and which orders run most efficiently. Decisions are no longer reactive — they are data-driven, with measurable impact on productivity and energy efficiency.
Digital transparency is the foundation of modern manufacturing. Yet many production companies ask the same questions:
A mid-sized metalworking company faced exactly this situation. Machines of different ages and types were running reliably, but production remained opaque. Downtime was detected too late, root causes stayed unclear, and decisions were driven by intuition instead of facts. Machine retrofitting became the practical bridge between reliable existing equipment and modern, data-driven production transparency.
With the Novo AI sensor and the WatchMen platform, everything changed. Machines were retrofitted without modification or control-system access. Real-time machine data created clarity across production, exposed inefficiencies early, reduced downtime, and optimized energy usage — a decisive step toward Industry 4.0 and data-driven manufacturing.
...Novo AI delivers objective process insights, fact-based decisions, and targeted operational support — all focused on continuous improvement and collaboration.
Entering digital machine transparency doesn’t have to be a major project. With Novo AI, you start fast, flexible, and risk-free — without high upfront costs or complex IT infrastructure.
Our starter packages are designed specifically for retrofitting individual machines — the ideal entry point into Industry 4.0 digitalization.
No risk. No long-term contracts. Measurable ROI from day one.
We support you in reviewing and applying for regional or federal digitalization funding — including the technical project description for your smart manufacturing initiative.
Scale step by step across your entire machine park — with transparent costs, flexible rollout planning, and full ERP/MES integration.
When everyone on the team understands how their work contributes to overall performance, collaboration becomes fact-based — supported by an AI-driven manufacturing solution that empowers rather than pressures. Machine retrofitting creates the foundation for this transparency by connecting existing equipment to real-time data without disrupting daily production.
Today, the WatchMen platform sits at the heart of daily production.
It prevents downtime, boosts productivity, reduces energy costs, and turns manufacturing into an intelligent, transparent, and future-ready operation.
Questions or interested in learning more? We’re happy to help.
DMG MORI, Mazak, Okuma, Haas Automation, Makino, JTEKT, GF Machining Solutions, Trumpf, Hurco, EMAG, CHIRON, MAG / MAG IAS, Hardinge, Amada, TSINFA, Sodick, Methods Machine Tools, Jyoti CNC Automation, Fanuc, Siemens, TRUMPF
Learn more: Capture Data from CNC Machines
TRUMPF, AMADA, Bystronic, Durma, Baykal, SafanDarley, Gasparini, Jorns, Hämmerle, EHT, LVD, Danobat, BLM Group, FACCIN, DAVI, WAFIOS, NUMALLIANCE, Herber, YLM, CML, REMS, Bernardo, KNUTH, HEZINGER, Stierli-Bieger, Altendorf, RAS, Pedax, AMB PICOT, Holzmann, Epple, LECHNER, HSM, TRACTO-TECHNIK, KRENN, BJZ, RASI, Vingriai, Reinhard Klein
Learn more: Capture Data from Bending Machines
TRUMPF, AMADA, Bystronic, Durma, SafanDarley, LVD, Baykal, Gasparini, Hämmerle, EHT, Jorns, CoastOne, Prima Power, Yawei, Ermaksan, Cincinnati, HACO, Deratech, Schröder, Ermaksan, JFY, Yangli, VLB Group, Dener, Vimercati, Dimeco, IMAC, G.A.D.E., Bernardo, KNUTH, Stierli-Bieger, HEZINGER, BLEMA, Epple, Holzmann, BPR, STR, Danobat, Eisele, Colly, Schechtl, HACO-Kingsland, RICO, Beyeler (heute Bystronic), Pullmax, Pivatic, Darley, UZMA, RASI, Reinhard Klein, Vingriai, LVD-EHT, Hämmerle, Metallkraft, Biegetechnik Müller, MUBEA
Learn more: Capture Data from Press Brakes
Union, TOS Varnsdorf, Scharmann, Dörries Scharmann, Wotan, Pama, JUARISTI, SORALUCE, FPT, Lazzati, Skoda, Ingersoll, Giddings & Lewis, Lucas, HBM Machines, Toshiba, Asquith, Berthiez, Lymco, You Ji, Kira, Nomura, Dainichi, Alesa Monti, Sacem, Sacem-Greda, FERMAT, Kuraki, Zayer, Huller Hille, SIP, Stanko, Binns & Berry, Devlieg, Kearns-Richards, Henri Line, Niles-Simmons, Colgar, Comev, Giana, Jobs, San Rocco, Heckert, Cincinnati Gilbert, Rambaudi, Csepel, Tos Hostivar, Mecof, Sachman, Hüller Hille, Mandelli, MTE, Boehringer, Rambaudi, Froriep, Naxos Union
Learn more: Capture Data from Drilling Machines
DMG MORI, Gildemeister, Mazak, EMAG, Okuma, Haas, Weiler, INDEX, Doosan, Spinner, Hyundai WIA, Takisawa, Colchester, Tornos, Hwacheon, Hardinge, Biglia, Monforts, Schaublin, Mischungen aus modernen CNC-Zentren und älteren manuellen Maschinen
Learn more: Capture Data from Turning Machines (Lathes)
Fräsmaschinen von 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, MTE, Deckel, Rambaudi, Giddings & Lewis
Learn more: Capture Data from Milling Machines
TRUMPF, Bystronic, AMADA, Mazak, LVD, Prima Power, Mitsubishi Electric, Eagle, HSG Laser, Bodor, Han’s Laser, Trotec, Coherent (Rofin), IPG Photonics, Raycus, Ermaksan, Cincinnati, MicroStep, HGTech, Golden Laser, Salvagnini, Dener, Yawei, Durma, Baykal, Dreis & Krump, Tanaka, Farley Laserlab, ACL, Koike, Penta Laser, Senfeng, Bylaser, ESAB Lasertec, Laserlab, Haco-Laser, HF Laser, Optonics, Mischung aus CO₂-Anlagen, modernen Faserlasern, fliegender Optik, Portalmaschine, Kombianlagen mit automatischer Be- und Entladung
Learn more: Capture Data from Laser Cutting Machines
Ekato, Netzsch, Ystral, Lödige, Drais, IKA, Hosokawa Micron, BHS-Sonthofen, Zeppelin Systems, Mixaco, VMI, Lindor, Winkworth, Silverson, Hockmeyer, Gericke, B&P Littleford, Amixon, Charles Ross & Son, Morton, PerMix, Henschel, Bühler, Lodige Process Technology, Hüttlin, Volkmann, Maschinenfabrik Gustav Eirich, Fielder, Diosna, Vortex, Lodige, Hüttlin, Hecht, Bepex, Matcon, Forberg, Romaco, Bohle, Teagle, Kemutec, Processall, Omga-Mix, Scott Turbon, Jaygo, Nauta, Lodige Werke, Eppensteiner, Mischtechnik Schwab, Allgaier, Alpine, MÜLLER Mischtechnik, Schugi, Littleford Day, Collette, Kestner, WAB Willy A. Bachofen
Learn more: Capture Data from Mixing and Stirring Machines
Behringer, KASTO, MEBA, Amada, Kaltenbach, Bomar, Beka-Mak, Ficep, Everising, Trennjaeger, Danobat, Pedrazzoli, Eisele, Hyd-Mech, Imet, Soitaab, Berg & Schmid, Pressta-Eisele, Rusch, Julia, Emmegi, Cosen, ExactCut, MACC, Tecnomac, Nishijimax, HUVEMA, Rusch, MEP, BSM, BTM, KMT, Voortman, Bianco, DoAll, Friggi, Thomas, SABI, Karmetal, Peddinghaus, Forte, Pegic, Kaltmeier, Säge-Union, Schanbacher, RASOMA, PNK-Maschinenbau
Learn more: Capture Data from Sawing Machines (Saws)
Schuler, Aida, Andritz Kaiser, Bruderer, Erfurt, SEYI, Komatsu, Mecfond, Chin Fong, AP&T, Beutler Nova, Fagor Arrasate, Bliss, Minster, Sangiacomo, SIMPAC, Sutherland, Manzoni, Stamtec, Heilbronn, Erichsen, Ebu, Smeral, Lasco, LVD, Wemhöner, Kraus, Fischer, Dreis & Krump, Balconi, Schmedt, Rossmann, Yadon, IMS, Weingarten, Voest-Alpine, Kaiser Pressen, Dunker, Peddinghaus, Sachs, Rossi, Neff, Kieserling
Learn more: Capture Data from Punch Presses
ELB, Blohm, Jung, Okamoto, Studer, Kellenberger, Reform, KEHREN, ABA, Geibel & Hotz, Tschudin, LIZZINI, Campbell Grinder, Lodi, WEMA, Voumard, Mägerle, Lodi Grinding, TOS Hostivař, Micron, Danobat, Palmary, Supertec, KUGEL, Tschudin, Koyo, Cylindrix, Tacchella, DELTA, Cincinnati Milacron, Jones & Shipman, KMT, Erwin Junker, Lodi, Fortschritt, REKORD, Stankoimport, Praga, Karstens, Reinhard Klein
Learn more: Capture Data from Grinding Machines
Arburg, Engel, KraussMaffei, Sumitomo (SHI) Demag, Wittmann Battenfeld, BOY, Haitian, Negri Bossi, Ferromatik Milacron, Fanuc, Toshiba, JSW, Dr. Boy, Italpresse, MAPLAN, Sandretto, Stork, Chen Hsong, LK Machinery, Tederic, Windsor, Hemscheidt, Battenfeld, Netstal, Hüller Hille, Welltec, Niigata, Toyo, Demag Ergotech, Ankerwerk, SIG Maschinenbau, Mir, Klockner Ferromatic, Satra, Battenfeld Austria, Anker, Hemscheidt Maschinenbau, Heinz Weiler
Learn more: Capture Data from Injection Molding Machines
Fronius, Lorch, EWM, ESAB, Kemppi, Cloos, Rehm, SKS Welding Systems, KUKA, Panasonic, Miller, Lincoln Electric, Migatronic, OTC Daihen, TELWIN, Dalex, CEA, Technolit, Helvi, Orbitalum, Oerlikon, Heron, TBi, Dinse, Carl Cloos, Saf-Fro, Cebora, Ideal-Werk, Fessmann, Hürner, Weco, Kjellberg, KEMPER, Böhler Welding, Soyer, Merkle, Elektra Beckum, Mennekes, Bavaria Schweißtechnik, Elektrodenwerk Bad Liebenwerda, Stürmer, Weltronic, ESM Schweißtechnik, Thyssen Schweißtechnik
Learn more: Capture Data from Welding Machines
SMS group, Schuler, Lasco, Beche, Müller Weingarten, Weingarten, Danieli, Siempelkamp, Wepuko PAHNKE, Fagor Arrasate, Banning, Hydralic Press Company, Schlebach, Ajax, Raufoss, Hasenclever, Mönninghoff, GFM, Niles-Simmons, Sack & Kiesselbach, Eumuco, Ernst Thielenhaus, Ernst Schubert, Dürr, Loewy, Sundwig, MPM, Maschinenfabrik Erfurt, Mavag, Rautomead, Waldrich Siegen, UnionChemnitz, Fagor Ederlan, SKET, Cincinatti, Farrel, HITACHI Zosen, Kobe Steel, Komatsu, Inoue, Omav, HMP, Eumuco, Makino, UBE Industries, Boehringer, Carl Wezel, Rautenbach, Naxos Union, Mannesmann Demag, Davy McKee, Aichelin
Learn more: Capture Data from Forming Machines
Krones, Bosch Packaging Technology (heute Syntegon), MULTIVAC, IMA, Rovema, Optima, Gerhard Schubert, Theegarten-Pactec, LoeschPack, ULMA, Marchesini, Uhlmann, GEA, Ilapak, Cavanna, Ishida, KHS, SIG, Bradman Lake, Pacmac, Fuji Packaging, Norden, Romaco, Coesia, HASSIA, HMC, Trepko, MGS, Volpak, ACMA, Cama Group, Tisma, OK International, Smipack, Econocorp, Viking Masek, Adco, Sepha, Wrapade, Aesus, Oystar, Waldner Dosomat, Klöckner Medipak, Kalix, Dividella, Oka, Bosch Cartoning, Hayssen, Mateer-Burt, Laudenberg, IWKA, SIG Pack, Mohrbach, BWI Manesty, Manurhin, Kisters, Klockner Bartelt, GRONINGER, Möllers
Learn more: Capture Data from Packaging Machines
Rosendahl Nextrom, Maillefer, Troester, Davis Standard, SAMP, MFL Group, EXTRUDEX, Sikora, Reelex, Queins
Learn more: Capture Data from Extrusion Machines
Niehoff, Maillefer, Rosendahl Nextrom, SAMP, MFL Group, Koch, Mario Frigerio, Henrich, Kieselstein, WAFIOS, Maschinenfabrik Niehoff
Learn more: Capture Data from Wire Drawing Machines
Sikora, Zumbach Electronic, Hipotronics, HighVolt, HFSAB, NDC Technologies, HV Technologies, Megger, BAUR, Phenix Technologies
Learn more: Capture Data from Cable Testing Systems
Schleuniger, Komax, Metzner, Kabatec, Artos, Metzner Maschinenbau, Eraser, Kingsing, Carpenter Manufacturing, Kodera
Learn more: Capture Data from Cable Shielding Machines
Niehoff, Maillefer, Rosendahl Nextrom, Setic, Pourtier, SAMP, Troester, MFL Group, SKET, Caballé, Queins, Watson
Learn more: Capture Data from Stranding Machines
Rosendahl Nextrom, Maillefer, SAMP, Niehoff, Windak, MFL Group, Sikora, Setic, Pourtier, MAG, Bühler, Voith, Aumann, Marsilli, Jota
Learn more: Capture Data from Winding Machines
Sikora, Zumbach Electronic, Rosendahl Nextrom, Maillefer, Beta LaserMike, NDC Technologies, Taihan, HFSAB, Hipotronics
Learn more: Capture Data from Spark Testers
Maillefer, Rosendahl Nextrom, Troester, Davis Standard, SAMP, MFL Group, EXTRUDEX, Queins, Reelex, Windak
Learn more: Capture Data from Jacket Extruders
WiCa, Niehoff, Maillefer, Rosendahl Nextrom, Setic, Pourtier, SAMP, MFL Group, SKET, Caballé, Bartell Machinery, Queins
Learn more: Capture Data from Bow Stranders
Windak, Rosendahl Nextrom, Maillefer, Niehoff, SAMP, MFL Group, Voith, Goebel IMS, Kampf, Atlas Converting, Kampf Schneid- und Wickeltechnik
Learn more: Capture Data from Drum Twisters
Niehoff, Herzog, Wardwell, Spirka Schnellflechter, OMEC, Steeger, Karg, Mayer & Cie, OMAC, KOKUBUN
Learn more: Capture Data from Braiding Machines
Maillefer, Rosendahl Nextrom, SAMP, MFL Group, Niehoff, SKET, Pourtier, Setic, Queins, WiCa
Learn more: Capture Data from Armoring Machines