There have been some exciting developments at our showroom in Schwendi-Hörenhausen: new machines, exciting additions, and fresh ideas for tomorrow’s manufacturing. These developments mark the next step in our strategy, which is why our showroom has now become the HAM Performance Center (HPC). And because our virtual tour provides a one-to-one digital representation of this location, we have also updated it accordingly.

You can now experience the digital process chain for machining online. Anytime. From anywhere. With just one click, you can dive right in and discover how modern manufacturing works today – networked, efficient, and practical.

The virtual tour takes you through all the relevant components. From process design and simulation to storage and tool preparation to use on the machining center. We clearly present each step and demonstrate how you can optimally integrate your processes. Thus the individual systems communicate with each other via interfaces and integrate flexibly into your existing production.

So with our HAM Performance Center, we are laying the foundation for THE technology center of the future – a place where digital innovation and manufacturing technology come together.

Whether you’re looking for inspiration, looking for specific solutions, or simply curious – updated content, new videos, and exciting insights directly from practice await you in the virtual HAM Performance Center.

Start now: Discover the 360° virtual HAM Performance Center

Do you have questions about the digital process chain? We are happy to help.

Der Beitrag A new look behind the scenes – our virtual HAM Performance Center is here! erschien zuerst auf HAM Präzision.

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:

Practical application: The digital process chain in live machining as part of our workshop “The HAMmer Smart Factory” on March 19, 2025

Der Beitrag The path to smart manufacturing: The digital process chain live at our workshop! erschien zuerst auf HAM Präzision.

The manufacturing world is at a turning point. With Industry 4.0, automation and intelligent production processes, the entire structure is changing – faster, more efficiently and more precisely than ever before. However, technological progress not only brings new opportunities, but also significant challenges: High investments, security risks in IT and the complex integration of new systems into existing structures are slowing down many companies.

Despite all the hurdles, digital transformation is no longer just a nice extra feature, but a decisive factor in remaining competitive. Companies that rely on networked production landscapes, smart maintenance concepts and digital processes benefit from increased efficiency, reduced downtimes and optimized quality assurance. But where do you start? How can proven processes be made fit for the future? And how do you manage to use digital innovations without losing flexibility?

These questions are groundbreaking and the answers to them could determine which companies remain at the top in the long term and which lose out.

The smart factory: networked production

Industrial production has undergone a profound transformation in recent years. Industry 4.0 marks the dawn of a new era in which machines, sensors and intelligent software interact seamlessly to make manufacturing processes not only more efficient, but also more flexible and predictive. The “smart factory” is not just a fad, but the consistent further development of modern production technologies. All processes are digitally networked so that data can be recorded, evaluated and used immediately for optimization in real time – an essential prerequisite for adapting quickly to dynamic market requirements.

In this digitalized environment, machines no longer act as isolated units, but as intelligent nodes in a finely tuned network. Through the use of IoT (Internet of Things) technologies, production systems communicate with each other continuously, coordinate processes autonomously and identify potential bottlenecks before they occur. The potential of this development is particularly evident in machining technology: machine tools are now able to diagnose wear at an early stage and independently initiate maintenance measures to avoid unplanned downtime – a principle known as “predictive maintenance“.

The digital transformation is no longer an optional addition, but an integral part of future-oriented manufacturing. According to the German Federal Ministry for Economic Affairs and Climate Protection, 95% of companies now recognize Industry 4.0 as an opportunity. In fact, more than half are already using Industry 4.0 applications. ¹ No wonder, as it not only increases efficiency, but also raises quality standards to a new level. Companies that take the step towards the smart factory rely on the intelligent integration of automation and networking and thus secure a decisive competitive advantage. In an increasingly networked economy, these technologies are the key to remaining competitive in the long term and preparing for future challenges. Those who make targeted investments in digital production strategies today are laying the foundations for sustainable, adaptable and future-proof production that meets the growing demands of the market.

More efficient, smarter, cheaper: the biggest opportunities of digital manufacturing

Digitalization is opening up completely new opportunities for the manufacturing industry. Not only can processes be made more efficient and cost-saving, they can also be controlled more precisely. Automation, networked machines and data-driven processes ensure that production processes run faster and more smoothly. Companies that take advantage of these digital opportunities benefit from smoother processes and a clear competitive advantage.

Automation is a key aspect of this. It replaces or supplements manual processes in order to increase productivity and precision. Intelligent systems and machines take over repetitive tasks, reduce manual intervention and minimize sources of error. At the same time, networked sensors provide valuable real-time data that can be used to continuously adapt and optimize processes. This helps to identify bottlenecks at an early stage, make better use of resources and shorten production times.

Digitalization also brings major benefits when it comes to maintenance. Instead of only repairing machines when they break down, intelligent sensors continuously record the condition of the systems (predictive maintenance). They detect wear and tear at an early stage and give a timely signal for upcoming maintenance. This not only reduces expensive downtimes, but also extends the service life of the machines and saves maintenance costs in the long term.

Not forgetting quality control. Digital measurement technology and AI-supported analyses detect even the smallest deviations in real time. This reduces waste, reduces reworking and ensures that the end products are of a consistently high quality. This is particularly important for companies that want to produce economically and sustainably.

Ultimately, digitalization is not just about efficiency. It fundamentally changes how production takes place and makes manufacturing processes more flexible, smarter and future-proof. Those who embrace this can secure long-term competitive advantages and respond better to new challenges.

Challenges: Where companies fail in the digital transformation and how you can do better

Digitalization in manufacturing brings many advantages, but also some challenges. Companies not only have to reckon with technological and financial hurdles, but also take organizational and security-related issues into account. Those who recognize and address these challenges early on can avoid typical mistakes and successfully shape the path to the digital future.

One major problem is the high initial investment. The introduction of new automation technologies, sensor technology and data-driven processes requires high financial resources. The total costs, especially for the integration of existing systems or necessary IT infrastructure, are often underestimated. Added to this is the lack of uniform standards, which makes it difficult to integrate different machines and software solutions. Without a well-thought-out digitalization strategy, the changeover can be expensive and inefficient.

IT security and data protection are also important issues. The increasing networking of machines, cloud services and IoT systems also increases the risk of cyberattacks. Robust security concepts with preventive IT security measures and employee training in the secure use of digital systems are essential. This is the only way to protect sensitive production data and ensure smooth operations at the same time.

The acceptance of employees should also not be forgotten. New technologies require new knowledge and not everyone is immediately enthusiastic about change. However, if employees understand why change is important, resistance can be reduced through further training and open communication.

Digital manufacturing is not just about technology, but also about strategy, security and people. Those who make the right decisions, keep safety in mind and involve their employees will remain competitive in the future.

Human vs. machine? Why the human factor remains crucial in digitalization

When talking about digitalization in manufacturing, the question often arises as to whether machines will take over our work at some point. Sure, automation through intelligent systems makes many things faster and more efficient, but they still need people. Machines don’t run on their own: they need to be monitored and adapted. This requires well-trained specialists who are able to solve complex problems and drive innovation.

Ultimately, it is the employees, with their technical expertise and creativity, who make the true added value of digital technologies possible in the first place. People remain irreplaceable when it comes to developing innovative solutions and finding the right strategy for digital change. That’s why it’s so important that companies to continuously train and educate their teams so that everyone understands how to make the best use of new technologies.

Digital manufacturing is not about replacing people with machines, but about bringing the two together. Machines ensure greater efficiency, while people use their experience and ingenuity to steer and further develop the digital transformation.

Conclusion: Digital progress won’t wait – set the course now

The digital transformation has long since reached the manufacturing industry. According to a PWC study, 64% of companies are still at the beginning of their digitalization efforts, but the digital pioneers are already investing 45% of their IT budget in transformation projects.² Automation, the use of data and predictive maintenance ensure that processes become leaner and quality increases. With concepts such as the smart factory and the principles of Industry 4.0, companies can shorten their production times and use resources more efficiently.

Of course, this progress also brings challenges – such as investing in modern IT structures and reliable security solutions. But more importantly, employees need to be involved. Their expertise and commitment are crucial if new technologies are to develop their full potential.

Those who invest in digital progress today are laying the foundations for sustainable and future-proof production. This is also confirmed by figures from the German Federal Ministry for Economic Affairs and Climate Protection: 91% of companies see Industry 4.0 as a prerequisite for maintaining the competitiveness of German industry.¹ Change will not wait – now is the time to take action.

Would you like to find out more? We will be happy to advise you when it comes to your smart factory. Visit our showroom and experience live how digital manufacturing works in practice. Contact us here and visit our HAM showroom, where you can experience digitally networked production live and up close.

Sources:

¹ https://www.bmwk.de/Redaktion/EN/Dossier/industrie-40.html

² https://www.pwc.de/en/strategy-organisation-processes-systems/operations/digital-factory-transformation-survey-2022.html

Der Beitrag Digitalization in manufacturing: Why now is the right time erschien zuerst auf HAM Präzision.