https://engtechgroup.com/cnc-machines-evolution/
https://www.marposs.com/eng/application/machine-tool-retrofit
https://www.marposs.com/eng/application/machine-tool-retrofit
2024
Case Study
Client Challenge
The need to adapt to Industry 4.0 standards with Adequate RoI.
Client Background:
A leading manufacturing plant specializing in precision engineering with Computer Numerical Control (CNC) technology faced challenges in optimizing production processes and ensuring the seamless integration of advanced technologies. The client, operating in a highly competitive industry, sought to enhance efficiency, reduce downtime, and elevate the overall productivity of their manufacturing operations.
2023
August 13, 2023
The role of 5-Axis CNC Machining in Industry 4.0
Reshaping Manufacturing through Technological Advancements
2021
Clea is SECO’s suite solution for the remote management of devices and machines
Clea is SECO’s suite solution for the remote management of devices, of data generated in the field, and its aggregation in the cloud to support business analytics. With Clea, you will have everything you need to enable your custom IoT solution: dedicated hardware, connectivity, a platform, telemetry, data management, analytics, and consulting.
A Case - Challenge
A manufacturer of industrial machinery for woodworking and the processing of other materials had the initial requirement to reduce warranty costs for CNC machines, computer controlled machining tools which are able to process materials without a manual operator.
What SECO did
SECO enabled the equipment of CNC machines with ad-hoc smart sensors and gateways, connecting them to EDGEHOG Device Manager to allow production cycle data analysis, remote control and update – with OTA updates – and predictive maintenance through dedicated algorithm. Connectivity was enhanced by equipping the machines with a global SIM card, Wi-Fi and Bluetooth connection and geo-localization microservice.
Results achieved
Making the customers’ machinery smart and connected allowed for offering a better user experience with the possibility of remote assistance with annual subscription. From a production standpoint, there was an increase in the quality of the pieces produced, while reducing production waste of 30%. The supply chain was provided with a better support, allowing cost (10%) and lead time (40%) reduction of the spare parts.
https://www.seco.com/en/case-studies/industrial-automation/smart-connected-cnc-machine
Mazak - Smart Machine Tool Developments
Mazak
The Global Leader in Machine Tools - Turning centers, Machining centers, Multi-tasking, Hybrid multi-tasking, Laser processing,
CNC technology, Automation and IoT solutions.
SMART Manufacturing Thanks to Smooth Technology
Today manufacturers everywhere face many challenges - constantly striving to reduce production costs, increasing the use of automation, a growing shortage of skilled employees among many others. "The Mazak iSMART FactoryTM" technology can be used to meet manufacturers' demands to establish production plants using the IoT. By utilizing advanced Mazak machine tools together with software, we can effectively support your goal of realizing data-driven manufacturing for higher productivity.
https://english.mazak.jp/machines/technology/factory-network/ismart-factory/
Mazak SmartBox?
Mazak SmartBox is a revolutionary launch platform for easy and highly secure entrance into the Industrial Internet of Things (IIoT). It is a scalable solution that connects your manufacturing equipment to your factory network and allows the free flow of information to your management systems via MTConnect® for Overall Equipment Efficiency (O.E.E.).
Mazak offers the smartbox in various configurations/kits based on the scenarios and challenges in which the units will be used. The device physically mounts to the side of machines without having to integrate into a machine’s electrical cabinet. One Mazak SmartBox may connect several machine tools along with other associated manufacturing equipment, depending on the application.
THE BENEFITS OF USING Mazak SmartBox?
Mazak SmartBox is designed to be a launch platform for anything IIoT. It:
Secures the machine from the network
Secures the network from the machine
Enables Edge/Fog computing and analytics
Uses MTConnect as standard supported protocol
Enables easy monitoring of equipment status and utilization
https://www.mazakusa.com/machines/technology/digital-solutions/mazak-smartbox/
Mazak Smartbox Implementation Case Study
The SmartBox is one of many innovative components in Mazak’s dynamic iSMART Factory concept, which enables complete digital integration of advanced manufacturing cells and systems to achieve free-flow data sharing in terms of process control and analytics.
The iSMART Factory concept also incorporates Mazak SMOOTH TECHNOLOGY, a complete process-performance technology platform that includes the various levels of the new Mazak MAZATROL Smooth CNC as well as advanced machine hardware and servo systems. SMOOTH TECHNOLOGY represents a key first step towards digital factory integration.
MACHINES AND OTHER EQUIPMENT
65 machines, paint test stands, and other devices are connected through MTConnect at the Kentucky Mazak factory. In the initial complete installation of a machine-monitoring system encompasses SmartBoxes, six horizontal machining centers (HMCs) in an automated flexible manufacturing system, three other HMCs in a similar automated system, and six large bridge-type milling machines.
A series of 60-inch display monitors presents real-time utilization data in the test section of the plant and cycles through a series of KPI reports that are viewable for short periods of time using MERLIN. The Cisco switch enables network isolation, which creates a higher level of cybersecurity for enhanced
machine monitoring and analytics. The majority of reports focus on a specific machine, and display performance-based gauges and readouts. Other reports compare all connected machines according to a variety of critical metrics, such as uptime and stoppages by category.
For the first time, for Mazak, top management, as well as everyone across the company’s shop floor, has access to the same actionable reports and/or monitored data through mobile devices. Shop floor employees now have easy-to-interpret, visual report formats that give them at-a-glance information
about how machine tool conditions are influencing efficiency. Bar graphs that summarize activity across several machines simultaneously inform supervisors and managers of trends useful for decision making and long-term planning, such as when additional operator training may be needed.
The company is now fully aware of program stops, feed holds, spindle overrides, tool changes, and other reasons why a machine is idle. By analyzing collected data, Mazak personnel are able to identify and easily fix such downtime-related inefficiencies to improve overall utilization. Another new advantage is that individuals, such as equipment suppliers, can log on to Mazak’s network and have access to only those machines Mazak permits through SmartBox technology
PROJECT RESULTS
Almost as soon as reports were produced on its plant floor, the company experienced a six-percent increase in utilization. Without any other actions taken, these immediate gains resulted from operators simply being aware of how their time management affected machine utilization. To date, efforts to
reduce downtime — as based on factory-floor report data — have yielded a more than double-digit percentage improvement in machine utilization for the monitored machines. As a result of this windfall machine capacity, Mazak reduced operator overtime by 100 hours per month and brought 400 hours
per month of previously outsourced work back in house.
Source: Complete Digital Factory Integration and the IIoT by Mazak- A Cisco Report
https://www.cisco.com/c/dam/en_us/solutions/industries/docs/manufacturing/smart-box.pdf
THE NUTS & BOLTS OF INDUSTRY 4.0 - MAZAK
Published: 06/07/2018
The reality of Industry 4.0 data analytics for a Mazak customer, detailing the needs and some of the benefits of easily applied system components suitable for SMEs
https://www.machinery.co.uk/machinery-features/the-nuts-bolts-of-industry-4-0-mazak
https://www.mazakusa.com/news-events/blog/artificial-intelligence-makes-spindle-health-monitoring-a-reality/
Implementation of a machine tool retrofit system
https://www.tib-op.org/ojs/index.php/th-wildau-ensp/article/view/19/10
https://www.bosch.com/stories/industry-4-0-retrofit-project/
https://www.bosch.com/stories/industry-4-0-retrofit-project/
2020
Strategic Retrofitting: Older Machines Get an IIoT Update
Affordable alternatives can help upgrade legacy equipment.
W. David Stephenson
MAR 10, 2020
Low-Cost Automation: Retrofitting Old Machines
https://www.industrialautomationindia.in/articleitm/358/Low-Cost-Automation:-Retrofitting-Old-Machines-/articles
3/23/2020
The Anatomy of a CNC Machine IoT Solution
https://www.productionmachining.com/blog/post/the-anatomy-of-a-cnc-machine-iot-solution
https://smartech.gatech.edu/bitstream/handle/1853/62850/NGUYEN-THESIS-2020.pdf
http://www.rae.ca/wp-content/uploads/industry_guide_sensor_technology_solutions_for_the_machine_tool_industry_en_im0018543.pdf
CASE STUDY
Retrofit Enables Threefold Increase in Capacity
Henshaw replaces legacy CNC system with programmable numeric control (PNC) to improve machining cell performance and flexibility
2018
https://www.sme.org/technologies/articles/2018/october/industry-4.0-and-cadcam-software-five-questions/
Machine tool retrofit to increase productivity, user convenience and safety
"PCU Retrofit for Sinumerik 840D" service offered for machine tools with a Sinumerik 840D pl controller
PCU-based (Panel Control Unit) controller updated
After a short retrofitting time, equipment is ready again for immediate use
https://press.siemens.com/global/en/pressrelease/machine-tool-retrofit-increase-productivity-user-convenience-and-safety
2017
https://www.americanmachinist.com/enterprise-data/5-ways-machine-tools-are-impacted-industry-40
IoT enabled CNC Milling Machine
IIT Madras B.Tech project 2017
https://www.tkbala.com/iotcnc
6/14/2017
Data-Driven Manufacturing: Retrofit Your Machines
The Fraunhofer Institute has developed a retrofit solution to upgrade production systems with network capability, enabling users of older machines to reap the benefits of data-driven manufacturing.
https://www.mmsonline.com/articles/data-driven-manufacturing-retrofit-your-machines
CNC Machine Sensors
2014
https://www.techna-tool.com/blog/importance-of-cnc-tool-sensors-in-modern-day-cnc-machines/
About CNC Machines
http://home.iitk.ac.in/~nsinha/CNC.pdf
Ud 19.12.2024, 8.10.2021
Pub 11.8.2021
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