e - Sensi, a Web based Real-Time Tool Life Monitoring System for manufacturing companies. Secured, Real - Time tool life monitoring software product. Phoenix Login designed Sensi software product for shop floor in industries to monitor tool life. A web- based graphical user interface (GUI) system that will provide graphical and tabular real-time and parts monitoring for each machine under site/ department / area. Each machine has color codes to identify the status such as normal, reach warning value, reach set value, reach stop value, corrective action, and so on. Reports, raw and corrective data, query, data management, configuration and online help are also available.

The system triggers warning messages and send email to concerned personnel. Once the tool or part reaches the expected tool life, the system shall trigger the machine to stop and also disable the “Start” button. User shall entry the cause of defect and corrective action to replace, rework, and reuse tool or part in oder to enable the “Start” button.

Features
Tool Life Management
Re corrective Action
Reports
Database Management
Query
Admin Configuration
Help

Estimated lifetime of the tool given the cutting tasks to be accomplished.
Available spare tools
The number of workpieces to be machined from the same type
Workpieces waiting for being processed on the given machine
Cost of cutting tools, scraps, delay in order completion

As a consequence, the management system can

lower the cutting conditions
initiate tool replacement
reschedule the tasks to be fulfilled with appropriate messages to other parts of the system
dual determination of available tool life (i.e by conventional analytical techniques and by on-line monitoring) Multisensor based monitoring of tool wear and breakage integrated use of symbolic (ES) and subsymbolic methods and as a result, reactive and adaptive behavior.

Benefits

e-Sensi is a specifically designed for Process driven companies who wish to stay on TOP of their Quality control Process in their manufacturing chain.

1.      Collect Real-Time data from any Measuring Equipment automatically (Real-Time).
2.      Validate the Measurement data and Display the Specification & Control Spec
         Limits.
3.      Verify Rule violation (X-bar, Range, 7-Point Rule Warnings etc.).
4.      Trigger Out-Of-Control Messages(via E-mail, FTP Servers, Provision to connect to
         CELL Controllers etc.).
5.      Trigger Off-Guard-Band Message(via E-mail, FTP Servers etc.).
6.       Store Raw data entries.
7.       Display Real-Time Equipment Status (Shop floor).
8.       Store Corrective Actions Entries.
9.       Display/Print Control Charts (Real-Time / On-line mode).
10.     Display/Print Raw Data (Real-Time / On-line mode).
11.     Display/Print Corrective Actions (Real-Time / On-line mode).
12.     Generate CPK reports for any give period/set of samples.
13.     Define New Specification /Control Limits.
14.     Generate CMK reports.
15.     Generate Technician wise Efficiency report.
16.     Generate Process Controller wise Efficiency report.
17.    Download Raw Data / Corrective Action for SPC analysis
18.   Generate reports on Sample Tests Out-Of-Control, Raw Data collected Process
          Controller wise, Off-Guard-Band entries, Corrective Actions entries, Elapsed time
          for machine Buy-Off etc.