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Software suppliers and tool and machine manufacturers are making great advances in digital processes to make CNC machining more intelligent and efficient. The Industrial Internet of Things (IIOT) has changed the business of machining parts. When was the last time you heard a reference to “tool and die”? We have long passed the manual process of forming dies for casting parts or milling parts and tools by hand. The latest advances in software have added a level of intelligence and sophistication to machining that is close to replacing people. But digitalization can reach beyond CNC machining to positively affect all areas in business.
Growing Digital Systems
The first step into Industry 4.0 was the change to CNC machining with the use of CAD/CAM systems. Robotics have advanced production alleviating the safety and time-consuming human interaction for processes such as handling raw materials, assembly, and product packing. The addition of sensor points attached to tools collects data on vibration, force, and temperature for cloud-based monitoring. One of our partners, DMG MORI took the approach of using what they refer to as a “Manufacturing Service Bus” to integrate their systems and software with other software suppliers, like ERP (Enterprise Resource Planning), and even integrate both manual and digitized processes. The result is end-to-end digitization for efficiency and connectivity to all aspects of the business covering a variety of areas:
Design and Efficiency – It all begins with the design. Initial data from CAD/CAM software plans more efficient machining with less material waste and more efficient tool paths, and now monitoring of that program sends data back for even tighter programming the next time. Monitoring data, of course, also provides real-time feedback that improves efficiencies during production and records information used in maintenance scheduling. See more on digitization on the shop floor in our Industry 4.0 blog.
Production Management – Data monitoring of your part production is only the beginning of production management. Digital data can connect to planning systems to manage order scheduling, inventory control, and even personnel assignments. One of the biggest advantages here is inventory control. Rough stock requirements can be forecasted based on sales and order scheduling to avoid costly delays by building supply chain flexibility where costs can be monitored.
Customer Relationship – Control of data also guarantees consistent lead times. This improves client relations and allows your business to expand to service even more clients with a digital thread that covers production on all equipment. A quick prototype can easily be merged into production, for example, through complete mapping of all machine scheduling activities. Clients can also be kept abreast of production and quality monitoring through easy communication of data. And new clients can be shown the production of their part through virtual simulation, or even “walked” through the shop on a virtual tour.
Sales – Digitalization is the key to growth and profitability in CNC machining. We know speed and price are always competing with quality on the machine shop floor. The client needs faster and faster turnarounds on quotations and production. Digitization improves sales by allowing for more accurate quotations in a shorter timeframe and detailed designs that do not compromise quality. Production monitoring means parts no longer need to be created from scratch with a full library of data available. These efficiencies on the shop floor translate to cost savings and data management that increases sales.
Tool Management – Tool producers are stepping into IIOT with digital catalogues that can seamlessly connect with CAD/CAM software. Not only does this save time in tool selection, but specs can add information, such as metal choice, that improves overall project design and speed. Tool wear is monitored so maintenance and replacement tools can also be scheduled with ease.
Digital technology is the link from design to the real world that is changing manufacturing. It is also helping fill the gap by easing young engineers well-versed in technology into the machinist’s world. With an aging workforce, this is another huge benefit of digitization. New interfaces and uses are appearing almost as fast as someone can dream them up. Even sharing monitoring data with machine tool builders is resulting in better machine design. Thinking beyond the shop floor, digitalization can reach beyond CNC machining to integrate all areas of finance, sales, and personnel through careful integration of digital systems.