FAQs - Frequently Asked Questions

Question 1

How do manufacturers calculate OEE with IoT data?

Accepted Answer

Manufacturers calculate OEE by multiplying Availability x Performance x Quality. Availability measures runtime against planned production time, Performance compares actual speed to ideal cycle time, and Quality measures good output against total output. With IoT data, continuous machine signals replace manual shift log estimates, giving teams more accurate downtime, cycle time, idle time, and production behavior data for each asset, shift, or line.

Question 2

What is the role of IoT in TPM and predictive maintenance?

Accepted Answer

In TPM, the goal is to keep equipment productive by reducing losses before they interrupt production. IoT supports TPM by capturing real-time sensor data from machines, then using that data to detect early signs of faults such as vibration changes, temperature shifts, abnormal cycles, or repeated stops. FloControl turns those signals into production and maintenance visibility so teams can reduce unplanned downtime and protect throughput.

Question 3

How does IoT monitoring improve machine utilization?

Accepted Answer

Machine utilization measures how effectively equipment is used during planned production time and is closely tied to the Availability component of OEE. The primary gap IoT monitoring addresses is availability loss, including downtime, idle time, setup overruns, and stoppages that reduce sellable output. In discrete manufacturing, 60% OEE is often typical, while 85% is considered world-class, showing how much capacity can be recovered from existing machines.

Question 4

How long does the application and onboarding process take?

Accepted Answer

Most applications are reviewed within 5 business days, after which an onboarding call is scheduled. Full onboarding typically takes 1–2 weeks depending on your partnership model and certification requirements. Referral partners can be operational within days of their onboarding call.

Question 5

What industries does SensFlo support?

Accepted Answer

SensFlo currently serves the Metalworking, Plastics, Food & Beverage, and Textile industries. Partners often specialize in one or more of these verticals. If your clients operate in an adjacent sector, contact us to discuss how SensFlo may apply.

Question 6

Can I participate in more than one partnership model?

Accepted Answer

Yes — many partners evolve over time, for example, starting as Referral partners and moving to Reseller as their SensFlo practice deepens. Hybrid models are also possible; for example, a hardware OEM may also pursue a Technology integration partnership. Our team will help you structure the right approach.

Question 7

Is technical training required for all partners?

Accepted Answer

Technical certification is required for Reseller, OEM, and Consulting Services partners, as these models involve deploying or embedding SensFlo for clients. Referral partners have no certification requirement. Technology partners have access to training, but it is optional.

Question 8

What's the difference between a Referral Partner and a Reseller?

Accepted Answer

Referral partners earn a fee by introducing qualified prospects to the SensFlo sales team; they're not involved in the sales process itself. Resellers bundle SensFlo into their own solutions, take responsibility for deployment, and earn a margin on the sale. Resellers can also certify their engineers to provide Tier 1 client support.

Question 9

What is not included in the ROI calculator estimates?

Accepted Answer

This model focuses on direct revenue impact from increased output. It does not account for reduced waste, improved quality, lower labor costs, energy savings, or other operational benefits that often accompany SensFlo deployment.

Question 10

Can I share these results with my team?

Accepted Answer

Yes. You can screenshot your results or schedule a review session with our team to walk through the numbers, validate assumptions, and discuss implementation planning.

Question 11

What inputs do I need to get started?

Accepted Answer

You will need: current monthly production output, estimated time savings or production increase percentage, revenue per unit produced, and estimated implementation cost. Your operations and finance teams typically have this data.

Question 12

How is break-even calculated?

Accepted Answer

Break-even is the point where cumulative revenue gains equal your implementation investment. It is calculated by dividing the total implementation cost by the monthly revenue impact from increased output.

Question 13

What goes into the implementation cost?

Accepted Answer

Implementation costs typically include software licensing, hardware sensors, installation, integration with existing systems, training, and initial support. The total varies based on facility size, complexity, and deployment scope.

Question 14

How accurate is the ROI estimate?

Accepted Answer

This calculator provides directional estimates based on your inputs. Actual results depend on your specific operations, implementation approach, and operational variables. We recommend using conservative estimates and validating assumptions with your team.

Question 15

How does pricing scale for textile facilities?

Accepted Answer

Pricing is based on monitoring points, production lines, and facility scope. The model aligns costs with operational value and material waste reduction. Detailed pricing structure and ROI modeling are available on our pricing page.

Question 16

What internal resources are required?

Accepted Answer

Implementation requires coordination with production and maintenance teams. SensFlo provides onsite training and deployment support. No specialized IT or data science resources are required for ongoing operation.

Question 17

Does this replace our MES system?

Accepted Answer

No. SensFlo complements existing MES and planning systems by providing real-time process visibility and anomaly detection. It does not replace production scheduling, order management, or inventory systems.

Question 18

How soon can ROI be realized in a textile operation?

Accepted Answer

Most facilities see measurable material waste reduction and throughput improvement within the first 90 days. Full ROI, including energy savings and quality gains, typically occurs within 12 to 18 months, depending on facility scope and baseline performance.

Question 19

How secure is plant data?

Accepted Answer

All data is encrypted in transit and at rest. SensFlo operates within your facility network security framework. Access controls are role-based and configurable. Data does not leave your operational environment unless explicitly authorized.

Question 20

Does this integrate with legacy textile equipment?

Accepted Answer

Yes. SensFlo is designed to work with both modern automated systems and older textile machinery. Sensors monitor process variables independently, providing visibility without requiring equipment upgrades.

Question 21

What equipment is required for SensFlo installation?

Accepted Answer

SensFlo uses retrofit sensors that monitor humidity, tension, laser precision, and line speed across cutting, dyeing, and finishing operations. No equipment replacement is required. Installation connects to existing facility network infrastructure.

Question 22

How long does deployment take in a textile facility?

Accepted Answer

Initial sensor installation typically completes within 3 to 4 weeks for a standard textile operation. Full data integration and AI-driven insights are operational within 60 to 90 days. Deployment is modular, allowing phased rollout across production lines.

Question 23

How does pricing scale for food and beverage facilities?

Accepted Answer

Pricing is based on monitoring points, facility scope, and operational complexity. The model aligns costs with compliance protection and operational value. Detailed pricing structure and ROI modeling are available on our pricing page.