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You would be hard-pressed to find a quality machine shop anywhere in the world that does not rely on CNC machines. Machine shops needed to embrace the new technology that merged computers with machining. The approach was based on much less robust computing, back in the 1950s, but the premise remained the same until the onset of intelligent systems that is the foundation of the next big change. The fourth industrial revolution, “will take what was started in the third with the adoption of computers and automation and enhance it with smart and autonomous systems fueled by data and machine learning,” states an article by Forbes. It is these enhanced new ideas that form the basis of three needed steps to embrace Industry 4.0 in your CNC machine shop.
A New Perspective
First is the realization that Industry 4.0 is present and real. Some would consider it is just an evolution of the third industrial revolution. The conversation of a digital thread in manufacturing is real. There is the ability to connect every piece of a business from accounting to shipping.
This encompasses a number of connection points and different software systems that speak to one another. The perspective to grow in this new evolution is a big one. It is beyond the shop floor. Embracing all aspects of information that can be digitized and then connecting them is going to take a machine shop to the next level of intelligent communication.
Training
The addition of robots and sensors in autonomous production lines doesn’t mean lost jobs. We think of machinists and operators no longer on the floor. Employment is robust in manufacturing, but jobs are changing. Intelligent manufacturing means taking the knowledge of those master machinists and applying that into machine language. That knowledge can be digitized as those skilled tradesmen retire out.
Currently, there is a skills gap and a workforce gap as machinists are ageing. There is more technical knowledge required and good high salaried jobs with that. Manufacturers are wise to partner with local colleges on the training programs they need to facilitate the new needs of their business and train from within for staff interested in advancing with the Industrial Internet of Things (IIoT).
There are growing opportunities for CAD/CAM operators and service and repair technicians. And don’t forget, as production increases, machines still require setup, monitoring, and maintenance. More machines mean more people.
Tools and Technology
The benefits of multi-axis machines are now available at a manageable price point. Adaptations to 3-axis machines or new purchases put the ability for connectivity into every machine shop. The addition of metrology, robotics, and tool management can be added to bring systems into more automation.
Working with tool and software companies that have a bold vision for digital threads will allow the implementation of systems at your own pace. Staff teams must be able to grow with the process as well as budget. Gains inefficiencies will produce great ROI allowing for further advancement. Many automation reports cutting production time by 75% while extending tool life.
Robotics and autonomous systems are not as far off as you may think.
The Future
Where will the future of IIoT take manufacturing? Intelligent data management is now capable of affecting manufacturing in progress. Cameras on tooling software can detect shape and distance for more accurate cutting capabilities. The use of cameras also provides feedback for improved performance in the design of both parts and tools and machines themselves. The software can guide a user on how to install a tool, or intuitively stop production. The digital thread can create teams working together from machine building, software applications, and machinists for increased performance. These three needed steps to embrace Industry 4.0 are just the start. There isn’t one company that offers everything available in Industry 4.0 for CNC machining, but each can do their part to see where it takes us.