Reliable Processes Through Paperless Manufacturing

Robin Bender designates another significant advantage: the fact that, thanks to digital setup sheets, the data is available in its entirety and immediately. “The entire package of information is available on demand not only at CNC machines but also in other areas, such as tool preparation. This means that personnel involved in presetting & measuring, as well as in the assembly of complete tools and clamping devices, also benefit from digital setup sheets,” he reports, adding: “Digital setup sheets from ZOLLER’s TMS Tool Management Solutions software contain all the information and data required to manufacture a component. They are therefore ideally suited to significantly speed up internal processes—from NC programming to the initial editing of a workpiece—and, above all, to ensure extremely reliable processes. Everyone involved always works on the basis of the same, approved data.” 

Always optimally clamped—the Fixtures software module 

Particularly in the case of recurring production jobs in series production, it is crucial to provide suitable and tested clamping fixtures quickly and reliably. The Fixtures software module makes a significant contribution to this. Within it, each fixture is assigned an ID number so that it can be precisely assigned at any time. All data on specific components, required standard elements (screws, nuts, bolts), and specialized accessories—such as necessary hand tools—are stored in a single data record. Additionally, further information, such as photos and videos on the design and assembly of the fixtures, can be created. As a result, work planners can access all the information required for the correct design and assembly of clamping devices at the keystroke on terminals. This information is centrally maintained by authorized specialists. This ensures maximum process reliability, guaranteeing that the fixtures are always assembled in the optimal configuration. Additionaly, measurement reports, measurement schedules, test plans, and timelines for the repeated measurement, inspection, and calibration of fixtures can be saved and displayed. This ensures that only suitable and approved fixtures are used in production. 

To ensure that fixtures that have been assembled once are available at short notice in the future, the Fixtures software module can be connected to the sophisticated stock management system of the ZOLLER TMS Tool Management Solutions software. This allows storage locations for fixtures to be organized and managed just as simply as for tools. 

Short lead times and maximum flexibility are increasingly essential for local manufacturing companies to produce in a way that is internationally competitive. However, both can only be achieved in connection with process reliability. Internal processes can be significantly improved, particularly through extensive digitization. This applies specifically to the transmission of information and data from NC programmers to machine set-up operators, as well as to the organization and management of tools, fixtures, and measuring and testing equipment. Christoph Zoller, Managing Director of E. ZOLLER GmbH & Co. KG, a family-owned technology company specializing in the cost-effective handling of cutting tools in Pleidelsheim, comments: “Digitally transmitted data offers several outstanding advantages. It is usually generated automatically and thus error-free, it is immediately available to all parties involved, and it enables traceable corrections at any time.”

Setting Up CNC Machines with Process Reliability 

Above all, the extensive information and data related to NC programs enter digitally from NC programmers into the systems of machine set-up operators much more quickly, simply, and reliably. This applies to the NC programs themselves as well as information on required tools and fixtures, and the materials and dimensions of blanks. Until now, the standard practice has been to use a collection (folder) of paper forms and data, which is handed out and passed on manually by NC programmers to machine set-up operators. 

To digitize and optimize this process, ZOLLER has integrated the “Manage Setup Sheet” module into its TMS Tool Management Solutions software. The contents of the digital setup sheet can be flexibly adjusted to meet specific requirements. Thanks to interfaces with 30 different CAD/CAM systems, the setup sheets are largely generated automatically during CAD/CAM programming. NC programmers only select the CNC machine to be used. The digital setup sheets contain NC programs as well as data on tools, fixtures, and blanks required by the machine set-up technician. As an option, administrative data on main, auxiliary, and setup times can be added. As Robin Bender, project manager for the TMS Tool Management Solutions software at ZOLLER, explains, it is simple to integrate additional information into the digital setup sheets. “This includes, for example, comments, drawings, photos, and 3D models of fixtures and clamping configurations, as well as videos of complete processes—such as the design of clamping devices and the clamping of blanks,” he explains. With this detailed information and these instructions, the digital setup sheets avoid time-consuming follow-up questions and tedious searches—for example, for required equipment and auxiliary tools. As a result, they ensure significantly greater process reliability. 

Detailed information on clamping devices and tools is contained in the respective ZOLLER software modules of the TMS Tool Management Solutions tool organization system. Depending on the configuration level and installation of the entire software suite, this information can be called up via a keystroke as a supplement to the setup sheet. This ensures that relevant personnel have access to supplementary information as needed. This applies, for example, to the assembly and inspection of clamping devices, as well as the assembly, adjustment, and measurement of complete tools. As a result, specialized personnel in work planning can work much more efficiently and with greater process reliability.