Located in Maconboylen, near Lake Constance, SMW AUTOBLOK Spannsysteme 's specialty factory is a company that primarily produces single-piece and small-batch custom chuck systems. The 48 employees work in two shifts and utilize 23 machine tools, including lathes, milling machines, and grinding machines.
Most of these machine tools are connected to a server that stores machining task data and CAM programs, but it's difficult to call it a truly usable network. One reason is that these machine tools use different CNC systems.
Version 1.2 of " Status Monitoring " offers up to four interfaces and new applications. Frank Arnold, the production planning manager, shared his experience with us.
01. Mr. Arnold, why do you want to increase the level of digitalization in special factories?
Frank Arnold : First of all, we actually have the necessary conditions. SMW already has CAM systems, central servers, ERP systems, and other very effective tools. But so far, these systems still cannot allow us to monitor the actual production situation in real time.
02. What information would you like to know in real time ?
For us, production transparency is crucial. We need to identify potential improvements as early as possible and discover that potential immediately. Based on the machine tool status provided by " condition monitoring , " we can directly find ways to optimize the process.
03. Do you have any cases in this regard?
I'll provide two case studies. One case shows a workpiece being processed by a machine tool. For production planning, " Status Monitoring " provides all the detailed information needed to create a production plan. If the processing speed is faster than planned, I can prepare and schedule the next task earlier than expected. If the processing time is longer than planned, I can adjust the plan and reschedule tasks. Therefore, production downtime can be avoided, setup time reduced, and overall time saved.
Moreover, you don't need to contact the machine operator frequently.
Yes, our machine operator colleagues don't need to report work status to me, and I don't need to collect this information from various sources. " Status monitoring " gives me a clear overview of all the necessary information, and every task is transparent. The second case is transparency, which is also a decisive factor. " Status monitoring " also helps us identify and analyze frequently occurring problems. Imagine: two similar workpieces experiencing the same problem during the same machining operation, using the same cutting tools. The worst-case scenario might be tool breakage and machine downtime. However, let's assume this problem only occurs once every few weeks. Because the machine operator doesn't remember the first occurrence of the problem a week ago, and might consider it a coincidence or a machine malfunction, they won't realize the problem will recur. This is a problem that is bound to recur, but it wasn't recorded at the time.
Therefore, it will not attract special attention when it reappears.
Absolutely correct. However, the " status monitoring " software allows me to immediately grasp all the information and all the task data. Therefore, I can quickly identify fault modes and collaborate with machine operators, CAM programmers, clamping personnel, and any other relevant personnel to find the cause of the fault. More importantly, we can find solutions.
Therefore, this approach can prevent the problem from recurring in the future and significantly improve the process. Furthermore, it not only prevents tool breakage but also protects both the tools and the machine tool, while simultaneously improving production quality. Of course, it can also systematically and substantially reduce the scrap rate.
04. What are your initial impressions of the 90 - day trial version of the " Status Monitoring " software currently being tested ?
Very effective. Simple, intuitive, and easy to learn and use. Using the " Status Monitoring " feature was a pleasure. The software provides exactly what we need without overwhelming us with its complex functions. It's a very economical solution. Furthermore, with the great assistance of Mr. Rubes from Haas Werkzeugmaschinen , connection to the testing machine was effortless.
05. What are your expectations for using " status monitoring " software to connect the entire production system to the network ?
Sometimes, we want our production planning system (such as our ERP system) to use " status monitoring " information in real time. This requires connecting all the machine tools together. Once all are connected, we can have a comprehensive view of the expected and actual status of the production machine tools. Calculations can then be performed, avoiding extensive checks, back-and-forth trips, and annoying unexpected events. Furthermore, it has become a new communication tool used by our department.
06. How do your employees and colleagues view the fact that information is readily available today ?
It's not about monitoring employees and their work, but about identifying areas for improvement. This is the goal we all strive for. Furthermore, we all believe that digitalization of production is inevitable. This will be a continuous, marathon process. If we don't start now, we will be overtaken by our competitors and miss out on crucial opportunities.
This software is currently available in version 1.3, and new software offers a 90- day trial. Please feel free to contact us if you require it.
Please call 010-80420000/80420123 or email [email protected] . Thank you!
