Automated Machines and Toolmaking

Topics / Industry trends
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Choose to make an investment in your workforce, and you will cement their place in your factory.

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You have already invested time, energy and money into training your staff. Identify staff who want to learn. There may be opportunities for them in all kinds of other business areas, with some extra training. They already have the base skills and knowledge of the factory and equipment, so the best thing you can do as an employer is harness that expertise and build on their enthusiasm.

Staff members currently overseeing machines might start focusing on better tool design. Those in dispatch or ordering might work more closely with customers. You may find you have employers with interests you never even knew about - just waiting for the chance to grow into roles in technology, data analysis or systems administration. Most importantly, investing in your people strengthens your relationship with them, encouraging them to perform even better and therefore feel more valued and recognised.

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How often do you consult with your operator or Chief Tool Designer on what technology your company should consider next? Those working the machines are the people with the experience and knowledge to get the best results from your investment.

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They are the key to your grinding capability and therefore company success. Consider how to upskill your teams on the latest automation and how it fits into your factory infrastructure. Make sure you give them opportunity to network at Industry events or trade fairs.

Social media is now the place to go to learn and discuss the latest tool grinding trends - and its free. With over 1, members it is one of the largest cutting tool peer forums in the world. Remember to consult the key players in your team from the beginning on what technology would best fit your business needs and use their insights to plan for a successful smart factory.

Automation in manufacturing requires a different set of skills. Remote access is the best option for this in terms of independent expertise and production, because the project partners are based, for example, in Finland, in Switzerland and at various locations in Germany. They can also refine the overall system remotely should new requirements arise.

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The robot has a payload of kilograms, and loads and unloads the two five-axis machining centers. As mentioned at the beginning, the multifunctional manufacturing system has an integrated, automated induction hardening system. The times when it does this are decided by the MMS cell controller, based on the current production planning. This means the robot is no longer just a transport system, but also a processing machine, where the entire induction hardening process is programmed offline, with conflicts completely simulated in advance, thus merging virtual and real production.

An essential requirement in the project was the desire for an intelligent machine sensor system, which not only automatically monitors each machining process, but can also teach itself unknown processes without external intervention. For example, if a tool is used for the first time for machining on one of the RX10 units, the system must automatically adjust, learn and save the process limits with regard to torque and vibrations.

In this way, static upper limits that indicate tool overloads are identified, while during the machining process, dynamic limits identify sudden signal changes, for example caused by tool breakage. This means that for every combination of tool, material, feed rate and speed, the machine sensor system receives a scenario that has been learned over a certain period of time and can then be called up whenever necessary. Thus, if a previously learned process with a specific tool is repeated on another workpiece, the system has all the correct parameters it needs for this.

In that time, those in charge of the project have still had to tweak many parameters to ensure that the automation solution meets all the requirements.

Highly automated one-off production – Industry 4.0 in practice

But this should not be surprising, because Industry 4. Automated machine tending systems with modular design. Make sure you give them opportunity to network at Industry events or trade fairs. Social media is now the place to go to learn and discuss the latest tool grinding trends - and its free.

With over 1, members it is one of the largest cutting tool peer forums in the world. Remember to consult the key players in your team from the beginning on what technology would best fit your business needs and use their insights to plan for a successful smart factory. Automation in manufacturing requires a different set of skills. Where you currently have machine operators overseeing each step, you will eventually shift to a future-led model.

Employees will be able to contribute their own knowledge to the overall production, from what the data tells them about different products, to setting up tools for grinding and designing better tools. The factory of the future needs specialised skills in areas like software programming, robotics engineering and information technology. It also requires planning for an unknown future, making best estimates about what will be needed in five, ten, or fifteen years.

Set your whole workforce up for success.

Audel Automated Machines and Toolmaking

Existing staff can learn from experts. Technology specialists can work with toolmakers to refine the end product. Your workforce might worry about the impact automation will have on them. Uncertainty is a productivity killer, and it can filter through to every part of the business.

If you have already embraced continuous improvement in your factory, you know one of the key tenets is having everyone add value at every stage. Having everyone on board creates a more efficient manufacturing system — one that all staff can feel responsible for. But beyond lean manufacturing, autonomy is one of the basics of employee satisfaction. Studies have shown that people who are given space to do their job well are more productive and more satisfied at work.