In manufacturing environments, process parameters like machine temperature, pressure, speed, and time impact outcomes in a variety of ways. Process variables can influence productivity, product quality, batch consistency, and more. When a critical process variable drifts out of spec, it can cause defects, waste, product recalls, and even safety hazards. If a forming press begins running slightly hotter than spec or a mixing process runs too fast or too long, it could impact product quality in ways that aren’t immediately obvious, leading to waste and dissatisfied customers.

Process monitoring enables you to measure and track each machine’s operation in real time and automatically alert staff when parameters are exceeded. This way, you can catch problems earlier, create more consistent products, and support continuous process improvement. It also logs historical data to spot and analyze trends, track variations, and identify recurring issues early—before they become costly.

Unlike production monitoring, which focuses on productivity and efficiency (how many things are produced in a given period of time), the focus of process monitoring is on how the products are made. Process monitoring is commonly used to ensure product quality, which is particularly critical for products that must meet regulatory compliance, and to inform predictive maintenance planning, which helps extend equipment life, reduce unplanned downtime, and let you get more out of your maintenance budget.