Tool management system reduces set-up times

Recently installed tool management and component scheduling software has contributed in reducing set-up times on two Matsuura CNC machines by more than 50%.

TOOLstat is an in depth tool management and component scheduling system comprising of different integrated modules to give you a fully universal tool and component scheduling system that can save you up more than 50% on set up times alone.

Recently installed tool management and component scheduling software, from FORELINK the engineering software company in Warrington, UK, to a major UK manufacturer, CP Desoutter in Hemel Hempstead, has contributed in reducing both set-up times on their two Matsuura CNC machines by more than 50% and current tool spend through rationalisation of similar tools.

The machines are run on a four shift basis and both have 11 pallet pool systems and 210 tool magazines with in the region of 150 various components passing through these machines, so imagine the task that befell Ian Perry, Production Engineer of CP Desoutter every day.

Perry says "Before the software was installed we were reliant on operator knowledge to determine which tools were built, where those tools were stored and what tools needed to be built".

"The documented tool set up data we had was thought to be sufficient, but proved to be inadequate and problematic when we had a change of personnel".

"With the advent of TOOLstat, all this is now taken care of, within a few moments we have all the relevant information available for a given schedule of components that we want to run on these machines." Brian Burridge, Strategic Project Engineer, adds: "the system has performed that well we have already purchased an additional seat allowing the operators to relieve Ian of the scheduling function".

"We are now currently working with Forelink to develop a similar system for use on our Traub mill/turn centres".

"The help from FORELINK to ensure the problem free integration of TOOLstat into our work flow was excellent and their willingness to customise the software to meet our demands has been a credit to them." "Part of that customisation process," explains Forelink's Ronnie Bryan, "was to automatically change the NC program work datum positions from one machine to another, eliminating the need to re-clock and reset the datum positions when changing components from machine to machine enhancing the core purpose of the system which is to reduce set up times." *Overview of how the system works - you will create a tool library made up of unique tool build assemblies, by giving the tool up to an 8 digit number i.e T1001 which you may call a 20mm dia.

carbide endmill (roughing).

This tool will have a set length, size and tool build.

You can also create a copy of the tool which will become its sister tool.

Each tool is made up of individual items i.e T1001 will be made up of a: 20mm diameter carbide endmill; 20mm diameter endmill adaptor and a pullstud These items are stored within the Stores Library.

The stores library can be used as a fully functional Stores Database or just to store certain information for viewing and print out purpose when scheduling components or operator setting.

Tools may have the same items for the tool build but a different tool length or used for finishing, for these tools you would create another tool number.

Now you have created a tool library you will need to create a Component library.

For each component you need to input a certain amount of information and the accuracy of this information will determine the accuracy of the scheduler.

The required information is obtained by using the NC file auto scan facility which will read the NC file and not only produce your tool list but an accurate cycle time together with individual tool times and non cut times etc A schedule is built up of the required components from a work to do list and with all this information in place it is a simple matter of selecting the component or components required for scheduling, choosing the machine or machines and pressing the button.

When scheduled TOOLstat will give you all the information you require.

1 - Full tool schedule list colour coded to give a quick visual indicator of the tool status.

2 - List of error tools.

3 - List of tools to be added to the machine.

4 - List of tools to be removed from the machine.

5 - Tool process list with the new tool position.

6 - Tool input list.

7 - Tool build for tools requiring inputting.

8 - Automatic NC convert converting Tool Numbers, Tool Pre selection, H numbers, D numbers and tool breakage for the new pocket location.

9 - Inserts tool length measuring cycles to the NC program for tools added to the machine.

10 - Insert automatic NC program updates (G10) when integrated to a tool pre-setter.

The system will allow you to monitor and schedule tooling for your production work schedule, predicting tool life, when the tools will need changing within the production schedule and where all your tools are located.

One of the options available is of live updates from the machine and an SMS messenger service direct to your mobile phone, Computer or PDA device warning of potential machine stoppages through tools nearing life end.

Detailed print outs for the operator to work to are standard, which all adds up to making drastic reductions in setup times from one component to another.

Some other benefits are listed below 1 - Reduced Setup time.

2 - Reduced down time due tool breakages and tools out of life.

3 - Reduced Stock levels of tool holder and cutting tools.

4 - No manual edits of NC programmes.

5 - More production engineer availability.

6 - Can be easily integrated to a tool pre-setter.

7 - Read and write to tool data chips.

TOOLstat answers all these questions: * Do you know what tools you have available for a machine or cells? * Do you know how many back ends you have? * Do you know what components require what tooling? * Do you know what tools are in which machines? * Do you know what tools can be safely removed from any machine? * Do you know what tools need to be added to run a work to do list? * Do you know where to find tools for the work to do list? * Do you know what items are required to build these tool assemblies? * Do you have too many tool holders and cutting tools?.

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