The path to smart manufacturing: The digital process chain live at our workshop!
Imagine a factory where gears not only mesh, but where ideas interweave to create groundbreaking solutions. A place where technology doesn’t stand still, but rather storms forward – faster, more precisely, more efficiently. This is exactly what our HAM showroom is. We launched it four years ago to provide a real insight into the digital process chain and to show what digital manufacturing looks like today and what it could look like in the future. Not a theoretical construct, but a functioning system that ranges from the first digital tool model to machining on the machine.
For us as a tool manufacturer, one thing is clear: precision tools are at the heart of every production process, but fully networked production requires more than just excellent tools. A digital process chain requires the perfect interplay of different components, from tool production to machining. That’s why we set up the HAM showroom together with strong partners. What started small is now a dynamic network that is constantly growing. Year after year, new partners join us to expand our processes with state-of-the-art technology and keep them up to date. After all, digital transformation is not a one-off project, but a continuous development process and this is exactly what our showroom reflects.
Networked production: the digital process chain
Modern manufacturing is more than just production; it begins long before and doesn’t end with the last chip. The digital process chain maps this entire process: from the initial tool model creation according to DIN 4000 to the final machining on the machine. A tool and other things, such as materials, operating resources, etc., go through several process steps in every company.
However, it is not just the physical components that pass through various stations; data and information must also flow seamlessly. Every manufacturing process spans several areas: Process design and simulation, procurement and storage, tool preparation and setup and finally, actual production. And this is precisely where smart manufacturing comes in. After all, what use is a perfectly assembled tool in the machine if essential data on measured values or tool life is missing? The answer is simple: nothing. Without precise information, valuable time is lost and with it efficiency and quality.
The digital process chain takes a holistic approach to production. It not only considers the moment when the tool meets the machine, but also all upstream steps. This is because the entire process is laid out in what is known as work preparation. And this is precisely where there is enormous potential for savings: less time, reduced costs and increased production quality.
What advantages do we achieve with our digital process chain?
Any production is only as strong as its weakest link. A single high-precision tool is not enough if the rest stagnates. Manufacturing is not a stiff construct. It lives, evolves and faces new challenges. This is precisely where our digital process chain comes in, as an invisible control center that intelligently links data, machines and processes. The result? Less downtime, more efficiency, maximum throughput.
Instead of transferring data manually and risking errors, seamless data consistency ensures that all information arrives exactly where it is needed. From the first planning step to final processing, all relevant values flow seamlessly through the entire process. Manual transfers and error-prone intermediate steps are a thing of the past. This not only reduces the risk of misunderstandings, but also the time spent on unnecessary corrections.
But data alone does not increase productivity. At the same time, machine time is used more efficiently. In the past, programming used to be done directly at the machine. This was a laborious and time-consuming process that resulted in valuable lost production time. Today, CAM systems perform this task in advance, while tools such as Vericut simulate the NC code before the first chip is cut. This not only prevents downtime, damaged tools, costly collisions and unusable parts, but also saves lengthy run-in processes and wasted material.
More machine running time, less downtime
At the same time the digital process chain ensures leaner processes. Shorter programming and set-up times, a reduced variety of tools and optimized stock levels ensure faster processes and lower costs. Everything is precisely coordinated, unnecessary steps are eliminated and the entire production runs smoothly like precisely timed clockwork.
Another often underestimated factor is the prevention of search times. Anyone who has ever spent precious minutes trying to find the right tool knows how quickly this time adds up. However, well thought-out tool management systems such as Toolbase solves precisely this problem. Every tool you need is available exactly when you need it – without tedious searching and unnecessary downtime.
With all these advantages, the digital process chain makes the difference between a production that works and one that is truly efficient. Fewer errors, shorter downtimes, lower costs and production that is ready for the demands of the future today. But what exactly does our digital process chain look like now?
Our digital process chain in action
In our showroom, we demonstrate how the digital process chain is perfectly integrated from the first step of planning through to final production. The starting point is tool planning with the ISBE Sketcher software. We use this innovative solution to design and plan special tools in 2D and 3D. In addition, digital twins of the tools are created that can be used throughout the entire production process. These enable seamless further processing of the data throughout the entire process chain.
We use Tooltracer for error-free management and integration of tool data. This web-based database guarantees error-free tool master data records from a wide range of tool manufacturers and transports the data via interfaces to all common shop floor systems, such as WinTool. The result: significant time savings of up to 80% when creating and adapting tool master data.
Once all the required tools have been imported into WinTool, they are virtually assembled with a suitable tool holder. The measuring programs for production are already defined and written in the work preparation phase. The combined tool list is then seamlessly transferred to the CAM program via an interface. This eliminates the need to manually create individual tools, which speeds up the manufacturing process considerably and allows programming to begin immediately.
SolidCAM‘s patented iMachining technology enables cycle times to be reduced and tool life to be extended. Thanks to a wide range of simulation options, you retain control of the programmed tool path at all times. The generated NC code is stored together with relevant production data in a digital NC folder. This means that the process is theoretically designed and can be transferred to production on the shop floor.
From theory to practice: transferring data to production
All relevant production data, such as measuring programs or NC codes, can now be transferred to the machine control system. The automatically generated loading list shows the storage locations of the tools so that the required components can be removed quickly and without errors. Thanks to the barcode scanning system, the removal is documented and the system automatically updates the stocks. If reordering is required, this is done automatically to avoid expensive downtimes.
The TOOLFIX system from Schunk guarantees safe assembly of the Schunk toolholders and HAM tools. For the subsequent measurement of the missing tools, the measuring instruction sent by WinTool is called up in the Zoller DNC system. The tools are measured fully automatically using the venturion 450 CNC setting and measuring machine and the data is transferred to the machine without errors and with process reliability. The tool magazine locations are updated virtually to ensure complete traceability.
After selecting the NC code, machining begins. The TC52 touch probe from Blum-Novotest determines the workpiece zero point of the raw material before high-precision HAM carbide and diamond tools in Schunk tool holders go to work. Air, emulsion or the innovative minimum quantity lubrication with the AerosolMaster from KNOLL ensure optimum cooling. The LC50-DIGILOG from Blum-Novotest enables tool measurement and monitoring directly on the machine. Deviations from the target value are compensated for fully automatically. The measurement report created can be clearly assigned to each finished component. The finishing touch is provided by the compact C12 5-axis machining center from Hermle, which produces cubic parts weighing up to 100 kilograms with maximum efficiency.
Would you like to experience the digital process chain for yourself? Arrange an individual appointment in our showroom today and see the benefits for yourself! You can watch a detailed presentation of our process chain here:
