Automate
your machine tools

Automated Process Control (APC) a plug & play solution between your measuring equipment, machine tools and CAM software
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Produce differently with APC (Automated Process Control).

Thanks to Ellistat's APC module and our machine learning algorithms, you can set up your machine tools in a single piece and achieve better quality results than with traditional SPC or manual correction.
Once the correctors have been calculated by the APC (Automated Process Control), they are sent directly to the machine to create a closed loop.

Our strengths

Connection to measuring equipment

Automatically import measurement data into Ellistat regardless of communication protocol (USB, Bluetooth, RS232, .txt files, etc.) to avoid any manual input errors.

Use of CAD files

Recover 3D files of your parts to automatically configure the APC module.

Connection to CNC machines

Send calculated corrections directly to the machine program, whatever the brand of control (Fanuc, Siemens, Mitsubishi, Mazak, Heidenhain, Okuma...).
Industrial office user using ELLISTAT's APC module

How does it work?

Two theses and 10 years of research have enabled us to develop machine learning algorithms for Automated Process Control (APC). Whatever the complexity of the part, whether turning, milling or combined, Ellistat's APC module automatically adjusts each machine tool (CNC). Thanks to this tool, the process is corrected as accurately as possible to limit process drift, and the system learns from its own corrections to improve over time.

Automated Process Control (APC) is therefore unquestionably at the heart of Industry 4.0, combining the need to automate machine set-up and improve production quality.
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APC makes machine tool automation a reality

Your earnings

-90%
Less scrap
-75%
Set-up times, machine stoppages
$20 K
Save
20k€ / machine / year

Key Automated Process Control functions

Connection to CNC machines

Send the calculated corrections directly to the machine program, regardless of the brand of control (FanucSiemensMitsubishiMazakHeidenhainOkumaTornosBeckhoff...)

Automatic calculation of correctors

  • APC automates the setting process: the setter produces a part on a machine, measures it and the Ellistat algorithm automatically calculates the corrections to be applied to the machine.
  • The process is corrected as accurately as possible to limit drift, and the system learns from these corrections to improve over time.

Configuration from CAD and CAM files

  • Simplified Automated Process Control (APC) configuration. Dimensional information is read from part CAD files. Machining mode information is imported directly from CAM files.
  • The APC is accessible to both large and small production runs, as set-up times are very short.

Real-time SPC

  • Real-time generation and updating of control cards (X-bar, R, P, NP...)
  • Create and display histograms in real time
  • Instant detection of drifts and anomalies
  • Alerts and notifications in the event of non-compliance

Calculation and monitoring of capability indicators

  • Calculation of Cp, Cpk, Pp, Ppk indices
  • Capability index trend monitoring
  • Analysis of process capability to meet specifications

Customizable SPC report

  • Create control reports with customizable templates
  • Export reports in various formats
  • Integration of graphs and statistical data in reports

Compliance with standards

  • ISO 9001, ISO 9100, ISO 13485 compliant
  • Compliance with FDA CFR 21 part 11 requirements

Integration with existing systems

  • Accessible on Premise / on Cloud, full web technology 
  • API for integration with MES, ERP and other production management systems
  • Import and export data via CSV files, etc.

Intuitive user interface

  • Customizable dashboards
  • Clear, intuitive view of control data
  • Accessibility via various devices (PCs, tablets, smartphones)
Request a demo

Our APC methodology: a pilot project!

5 days of support

1 APC license with automatic correction on the machine

Weekly follow-up by our project managers

Our methodology

Your feedback

The implementation of Ellistat APC in our manufacturing facility has enabled us to make a shift towards Industry 4.0 and to make a smooth change towards a better organization of our production workshop. The "APC" module is very ergonomic and easy to use, which enabled us to deploy the solution quickly. Today, six months after deploying the software in our workshops, we are seeing a reduction in production rejects and a reduction in the costs incurred by machine adjustments. For the first parts processed with Ellistat, we have gone from a Ppk < 1 to a Ppk ≈ 1.4 and we can now set up our machines in 1 piece. The software has convinced everyone working with the APC, in their opinion: "Despite the fact that Ellistat has changed the way we set up and control our machines, it's nice to no longer have the stress of making mistakes when calculating offsets, whether when setting up or changing tools. What's more, we can really see the improvement in quality and comfort in the field.
Guillaume PERRILLAT-MONET
Project engineer, LTM SA
Equipping our workshops with Automated Process Control via Ellistat has radically changed the way we set up and operate our machines. We can now develop a new, more dynamic and efficient culture of variability control, with tangible results in terms of quality and productivity. Production staff gain real working comfort, and we can easily envisage greater complexity - the possibilities are enormous!
Alexis VULLIEZ
4.0 Projects Manager, KARTESIS
At LISI's Melisey site, the Ellistat APC module interfaces with LISI's MES, and corrections are transferred directly to the multispindles. The implementation is fast and the software is intuitive to use. The LISI team was pleasantly surprised by how the APC module was able to render the manufacturing process autonomous. Adjustment used to require several iterations, consuming several parts to reach the required level. Now, a single part is enough. The saving in set-up time achieved by using APC represents around 75%. By January 2021, the scrap rate had fallen from 3.5% to less than 0.1%. This is because the algorithm auto-corrects the machine tool in near-real time as soon as it deviates, resulting in a reduction in scrap rate of around 95 %. In early 2021, the APC solution was deployed on some twenty CNC machines of different brands and generations. Deployment is rapid, requiring little hardware and investment.
Anne-Delphine BEAULIEU
Member of the Lisi Group Executive Committee
All you have to do is measure the part, enter the data into the APC, which automatically makes all the corrections at once. This makes the employees' work much easier. Before APC, if the drift remained within tolerance, the setter had two options: recenter the dimension or leave it within the acceptable limit. With APC, the dimension is always centred. We've achieved our quality objective and improved our productivity: set-up time has fallen by around 50%, and the company's overall scrap rate by around 30%.
Vincent SKRZYPCZAK
CEO Azurea Unipessoal (Portugal)
With the implementation of APC on our multispindle lathes, we have achieved very convincing gains on several levels: reduced machine downtime, improved OEE and a clear reduction in the scrap rate. What's more, our scrap rate has fallen from 4% to 1.5%, and we can now space out inspection times, as the software guarantees us stability in machine variability.
Laurent MARTIN
General Manager, Joseph Martin
Machine tools machining a revolutionary part with automated process control

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