Process reliability through paperless production

Robin Bender points out another significant advantage: the fact that data is available comprehensively and immediately thanks to digital process sheets. The entire information package is available for retrieval, not only on CNC machines, but also in other areas, such as tool preparation. This means that staff also benefit from digital process sheets during setup and measurement, as well as during the assembly of complete tools and clamping equipment», he reports, adding: "«The digital process sheets in ZOLLER's TMS Tool Management Solutions software contain all the content and data needed to manufacture a component. This makes them ideal for significantly speeding up internal processes, from NC programming to the first machining of a workpiece, and, above all, for making these processes extremely reliable and secure. Everyone involved always works on the basis of the same approved data.» «

Always optimally clamped – the clamping devices software module 

Especially in repeated production orders in series production, it is important to have suitable and tested fixtures available quickly and reliably. The Fixtures software module contributes significantly to this. In it, fixtures are assigned an identification number so that they can be accurately assigned at any time. All data relating to specific components, necessary standard elements (screws, nuts, bolts), and specialized accessories, such as necessary hand tools, are stored in a data set. In addition, it is possible to create additional information, such as photos and videos about the assembly and installation of the devices. This means that, at the touch of a button on the terminal, work planners have all the information they need for the correct assembly and installation of the tensioning equipment. This information is maintained centrally by authorized specialist personnel. This ensures maximum process reliability, so that the devices are always assembled in the ideal configuration. In addition, measurement protocols, measurement plans, tests, and schedules for repeated measurements, checks, and calibrations of the devices can be saved and displayed. This ensures that only suitable and approved devices are used in production. 

To ensure that the fixtures, once assembled, are available at short notice in the future, the Devices software module can be connected to the sophisticated storage management of the ZOLLER TMS Tool Management Solutions software. This means that the storage locations of the fixtures can be organized and managed with the same simplicity and ease as tools. 

Short cycle times and maximum flexibility are increasingly necessary for local manufacturing companies to produce competitively on an international scale. However, these two objectives can only be achieved in combination with process reliability. Internal processes can be significantly improved, particularly through large-scale digitization. This specifically concerns the transmission of information and data from CNC programmers to machine setters, as well as the organization and management of tools, devices, measuring and control equipment. Christoph Zoller, managing director of the family-owned technology company E. ZOLLER GmbH & Co. KG in Pleidelsheim, which specializes in the economical management of cutting tools, says: Digitally transferred data offers several exceptional advantages. It is usually generated automatically and therefore error-free, is immediately available to all parties involved, and allows traceable corrections to be made at any time. »«

Process reliability for CNC machine equipment 

Detailed information and data relating to NC programs in particular can be transmitted much more quickly, easily, and reliably digitally from NC programmers to machine setters. This includes the NC programs themselves and information about the necessary tools and devices, as well as the materials and dimensions of the blanks. Until now, it was common practice to have a set (folder) of paper forms and data, which was handed over and transmitted manually by NC programmers to machine setters. 

In order to digitize and optimize this process, ZOLLER has integrated the Manage Program Sheet module »into its TMS Tool Management Solutions software. The content of the digital program sheet can be flexibly and individually adapted to specific requirements. Thanks to interfaces with 30 different CAD/CAM systems, the program sheets are largely created automatically during CAD/CAM programming. The NC programmers only select the CNC machine to be used. The digital program sheets include the NC programs as well as the data required by the machine setter regarding tools, fixtures, and blanks. Optionally, commercial data on primary, secondary, and setup times can be added. As Robin Bender, project manager for the TMS Tool Management Solutions software at ZOLLER, explains, additional information can also be easily integrated into the digital program sheets. « This includes, for example, comments, diagrams, photos, and 3D models of fixtures and clamping situations, as well as videos of entire processes, such as the structure of clamping fixture assembly and the clamping of blanks», he explains. Thanks to this detailed information and instructions, the digital program sheets eliminate the need for time-consuming inquiries and laborious searches, for example to find the necessary equipment and auxiliary tools. They thus ensure significantly greater process reliability. «

Detailed information on clamping devices and tools is included in the corresponding ZOLLER software modules of the TMS Tool Management Solutions tool organization system. Depending on the level of expansion and installation of the entire software package, this information can be called up in addition to the program sheet at the touch of a button. This means that the relevant personnel can view additional information when needed. This includes, for example, the installation and inspection of clamping devices as well as the assembly, parameters, and measurement of complete tools. This allows specialist personnel to work much more efficiently and with increased process reliability when preparing for work.