Why your adaptive controller might be causing the defects it’s trying to prevent

A field note on over-cautious process control, and the margin hiding in your own sensor data. In one engagement: the force the controller watches stays low across speeds, while sidewall wear spikes at the crawl. “Slower is safer” is the most expensive assumption on your shop floor. Most adaptive controllers are built on it. When cutting force climbs, the controller slows the tool; when force…