Insight Welding Information Management Systems
Actionable information and advanced process controls to drive your business forward.
To take your business to the next level, you need talent, drive, determination ... and Insight welding information management systems. Developed by Miller to help welding operations increase productivity, improve quality and manage costs, Insight systems can be among the highest-returning investments you make in your business.
If you want to monitor welding process outputs to compare the performance of different weld operators, work groups, devices or shifts ... if you need to better manage advanced welding and fabrication processes ... or if you simply want to be more competitive and profitable ... there's an Insight system that can work for you.
What's the right Insight welding information management system for you? It depends on the Miller® power sources you currently have, or plan to upgrade to. See the graphic below for Insight system compatibility with Miller equipment.
A simplified, Internet-based weld data solution that collects, rapidly transmits and presents actionable information to any Web-connected device in the world.
- Manage costs. What are your true welding costs - and where are your best opportunities to reduce them? Insight Core can help you find out.
A complete overview of essential performance metrics about your welding operationAsset Tree
An inventory of power sources within your fleet that are enabled with Insight Core - organized by building, department or machine - showing real-time activity status iconsProductivity Dashboard
Instant visibility of arc-on time and wire deposition, by location, by work cell or by power sourceGoals Dashboard
Shows progress toward continuous improvement goals you set for improving arc-on time, deposition rates and arc startsEvents Dashboard
Provides a record of welder uptime, connectivity, and machine-level events and errors as they occurQuality Dashboard
Real-time analysis and reporting of every weld made, revealing when quality fails to meet established thresholds for amps, volts, and WFS
Main Dashboard - Daily Status Overview
With Insight Core, you'll get more than just raw weld data. You'll get real information you can use to make positive, impactful decisions:
- In-depth information is available in reports that can be easily modified and displayed in a wide variety of customizable formats.
Available for Axcess® power sources and for 14-pin compliant power sources using an easy-to-install upgrade module, Insight Core can help you get the most out of your existing Miller® welding fleet.
How it works:
- Dashboards and reports are available using a browser on any Web-enabled device.
Online Simulator. Hands-on experience with an actual Insight Core welding information management system click here.
14 pin compatibility learn more
Insight Core Brochure
Advanced, real-time operator feedback to provide process control - to maximize quality and efficiency in welding and fabrication.
Welding and fabrication are complex processes. Even the best weld operators can benefit from assistance. With Insight Centerpoint, weld operators get immediate guidance and feedback. You'll get assurance that welds have been properly completed - and much more.
Leverage your investment in current
Axcess power sources by upgrading
to Access E functionality.
Factory Network Deployment with
Insight Centerpoint™ and PC for
Operator Interface - Maximize the benefit
by having a graphical HMI in each station to
provide instant feedback and assistance to
Which system is right for you?
Every welding operation has different needs. Here's how to choose the right Insight welding information management system to meet yours.
Review the chart below to compare selected key features of Insight Core™ and
Insight Centerpoint™ that can benefit your business. Some manufacturers benefit
from a combination of both systems, pairing each with the weld machines and processes it best supports.
|Integrates with Axcess and Auto Axcess power sources|
|Integrates with Axcess E and Auto Axcess E power sources|
|Integrates with 14-pin compliant Miller power sources|
|Web-browser based: no software required|
|Key Performance Indicators (KPIs)|
|Weld detail: amps, volts, weld duration|
|Productivity: arc-on time, wire deposition (on Axcess only)|
|Quality: evaluates every weld compared to pre-defined threshold limits|
|Goals: definable targets to improve arc-on time, deposition, arc starts|
|All information reported by date/time, work cell, shift and machine|
|Business Intelligence Tools/Reports|
|Real-time notifications of key events|
|Comparison reports available for any combination of machines and weld cells|
|All reports capable of exporting to Microsoft Excel-compatible format|
|Advanced reports to analyze welds, parts, productivity, and more|
|Capable of reporting OEE (overall equipment effectiveness)|
|Cost calculator: total cost for wire, gas, electricity, and labor per weld and part|
|Advanced Real-Time Process Control|
|Part Tracking™: visually and sequentially guides operator through weld process; monitors each weld for current, voltage, wire-feed speed, duration and gas flow (optional)|
|WorkFlow™: flexible system that governs the entire welding and fabrication process by providing visual non-welding work instructions in addition to the benefits of Part Tracking|
|Monitors pulse width/frequency, short circuit frequency, peak/background current/voltage|
|Energy/heat input calculation for total welded/assembled parts|
|Real-time operator alerts of activities such as over-/under-welding, missing/incomplete welds, sequencing errors, sequential weld guidance for the operator|
|Internet-based data storage|
|On-site data storage|
Case studies, technical papers, videos and more to demonstrate the power of Insight welding information management systems.
Frequently Asked Questions
Want to know more about Insight welding information management systems?
You've come to the right place.
Q. I already collect weld data. Why do I need another data-collection solution?
A. If you're collecting weld data manually, you know the process is time-consuming. It can also be prone to errors. It is difficult to capture all the information you need to identify opportunities for improvements in weld quality or productivity, and it can't deliver information in real time. Manually collected welding data also needs to be compiled, interpreted and analyzed before decisions can be made. Insight Core™ and Insight Centerpoint™ can eliminate these pain points.
Q. How is welding information different than arc data monitoring?
A. Arc data is only that: data in the form of numbers. Insight Core and Insight Centerpoint systems translate arc data automatically in real time, delivering actionable information you can use to make effective business decisions.
Q. What's the difference between Insight Core and Insight Centerpoint?
A. Insight Core is focused on providing basic productivity and quality information about the welding process. Insight Centerpoint brings advanced process control information into the actual weld cell to help manage the welding and fabrication process. Some manufacturers benefit from a combination of both Insight Core and Insight Centerpoint.
Q. Do I need to purchase new welding machines to use an Insight system?
A. Current Miller MIG 14-pin compliant power sources can be connected to Insight Core using field upgrade modules; new Axcess® machines can be ordered with Insight Core factory installed. Additionally, a module for Insight Centerpoint is available for Axcess machines as either a field upgrade or factory installed.
Q. How complicated is it to install an Insight upgrade on my machines?
A. Installation doesn't have to be complicated. Insight systems can be easier to get up and running than other welding information management systems. Insight Core connects via either wired Ethernet or an integrated Wi-Fi feature. Insight Core also includes convenient USB support for device setup, data downloads, and firmware updates. Axcess E with Insight Centerpoint is Wi-Fi capable using an external wireless switch (not included).
Q. Do I need to install special software to use an Insight system?
A. Insight Core requires no software: this system securely delivers information and reports to virtually any Internet-enabled device in the world - including tablet computers and smartphones. Insight Centerpoint has advanced welding and fabrication management processes that operate using dedicated PC software installed locally on the shop floor on a dedicated server.
Q. Can I look at the weld information in different ways?
A. Insight dashboards can provide an easy-to-understand snapshot of your welding operation's productivity, quality and progress toward goals. When more-detailed information is required, Insight can deliver it in easy-to-read reports, tailored to meet your specific needs.
Q. What can I do with welding information?
A. Welding information provides valuable insight into your operation that can help make it more competitive and more profitable.
Insight Core systems:
- Deliver vital facts about weld arc details (arc-on time, deposition, quality, process parameters)
- Reveal information about adherence to established weld thresholds for amps, volts, wirefeed speed
- Show your operation's progress toward productivity goals
- Notify you of key events in real time
- Deliver reports comparing any combination of machines and weld cells
Insight Centerpoint systems:
- Have advanced monitoring and process control capabilities
- Guide operators through complex weld processes and monitor each step of the way
- Alert/notify operator of missed and out of sequence welds
With Insight systems, you'll get valuable information you can use to increase productivity, manage costs and improve weld quality.
Q. Who can see my company's data?
A. Only persons to whom you give login credentials can see the data. Insight systems require input of a valid username/password combination before access to data is granted.
Q. How secure is my data?
A. Insight Core data is held securely in a Microsoft data center. This data center has ISO 27001-2005 accreditation with backup power generation capability and co-location redundancy. Insight Centerpoint data is stored on customers' on-site computers.
Q. Is there a subscription fee for Insight Core?
A. Insight Core doesn't require any subscription fees to access its cloud-based data storage, which maintains a rolling 90-day window of data.