User Case: Central Data Platform Connects the Shop Floor and Increases Efficiency
BERG, a clamping system manufacturer from Germany, decided to introduce a digital process network with a central COSCOM data platform in order to connect its previously isolated IT solutions in production into a powerful overall system. All production information is now clearly presented via a single user interface. Data from various applications — including the ESPRIT Edge CAD/CAM system and the HAIMER tool presetting device — is consolidated and displayed at a glance in a task-oriented manner. Production data is visualized via COSCOM InfoPOINT terminals located directly next to the turning and milling machining centers.
Reliable, Innovative Pallet Clamping
BERG is known for its low-profile clamping heads and zero-point clamping systems. These systems act as an interface between the machine table and the pallet, making them particularly suitable for automated pallet changing. The aim of these designs is always to generate high holding force with minimal applied force.
The company specializes in the design and high-precision manufacture of modular clamping systems for all standard interfaces used in gear and motor spindles.
Another component of the product portfolio is rotary unions for transferring media such as cooling lubricants, air, or hydraulic oils. BERG’s machine park includes a total of 18 turning and milling centers as well as grinding machines, some of which operate in double shifts and are run by around 30 employees.
A modern building complex houses approximately 5,000 m² of production space. The company is also particularly proud of its extremely low manufacturing tolerances of ±1 µm for four jointly manufactured zero-point clamping systems — a level of precision that is difficult to replicate.
At the Forefront – Also in Terms of Digitalization
The implementation of the COSCOM ECO-system represented a major step for BERG. The previously used DNC service from DLoG could no longer be installed after the transition to modern computer and IT structures. Support had also been discontinued after the supplier was acquired by a larger company.
The previously used tool management system also caused difficulties. A mandatory upgrade from the manufacturer would have been in the same price range as purchasing a completely new system.
“Experience forced us to look for alternatives. That’s when we came across the concept of satellite connections with a central platform and the modular solution offered by COSCOM in Ebersberg near Munich. We quickly realized how much this could move us forward. COSCOM’s promise of long-term support also confirmed that we had made exactly the right decision,” recalls Oliver Oberkoch (CAM programming / production planning).
Dirk Deppe adds:“We knew we were embarking on a longer journey toward digitization and that there would be a lot of work involved. But we were pleased to have a single point of contact.” After all, internal data first had to be harmonized and interface issues clarified with the providers represented within the company. “It would have been extremely difficult for us to handle this on our own,” recalls the member of mechanical manufacturing.
Ingo Kolberg, Senior Sales Manager at COSCOM, also looks back on that time: "On our recommendation, BERG decided not to simply replace one tool management system with another. Instead, we emphasized the advantages of using future-proof processes and data — including production information, machinery, NC programs, tool management, and production-related ERP data — all controlled via a central data platform.” The focus was placed on the complete article reference of the production order, from the NC program through to machining — in other words, the entire process chain. “And what was promised was delivered. Today, everything is clearly structured. For each article, all relevant process information is displayed centrally in a single digital production data sheet,” says Oliver Oberkoch enthusiastically.
Everything Revolves Around the Central COSCOM ECO-system
COSCOM’s new process network connects the internal system landscape with its “satellites” on the shop floor. The central data hub is FactoryDIRECTOR VM (Virtual Machining), where all production information is stored in a structured manner. This includes article master data and work plan data from the ERP system. BERG uses APplus as its leading ERP system. All data and information generated on the shop floor is now assigned to the versioned production item and the corresponding work sequence within the work plan in the central database.
FactoryDIRECTOR VM serves as the operational hub for integrated application systems such as:
- the ESPRIT Edge CAD/CAM system
- virtual machines
- turning and milling machining centers
- the HAIMER tool presetting device
Production data is visualized exactly where it is needed via InfoPOINT VM terminals located close to the machines.
All Together at One Table
Integrating satellite systems cannot be taken for granted. In fact, it requires significant coordination and project management – areas in which COSCOM has built up extensive expertise for more than 40 years. “To ensure that all systems work together smoothly, many different interests must be aligned and coordinated,” explains Ingo Kolberg. The project team therefore included internal project management and shop floor users at BERG as well as system providers such as APplus, Pimpel (ESPRIT CAD/CAM system), and HAIMER Microset (tool presetting device).
Taking the lead in process integration is essential. As Kolberg notes, “many system providers focus on selling their products but do not employ their own process integration specialists.” Numerous satisfied customers and integration partners demonstrate that COSCOM has earned its reputation as a “director” of complex digital production environments.
“Renowned system, tool, and machine manufacturers now approach us to ask how their data should be provided so that it can be optimally used for shop floor digitization. We rely on modern REST services and other contemporary communication technologies to connect these systems effectively,” says Kolberg.
The company also maintains close cooperation with CAD/CAM providers. “Some even have their interfaces certified by us. But we don’t talk to customers about interfaces – we talk about the benefits of integrated processes to achieve their specific digitization goals.”
For BERG, this integration brings clear advantages. Digital twins of tools help optimize setup times and increase tool reuse by providing transparency about which CNC programs previously used a specific tool.
ToolDIRECTOR VM can also communicate directly with the CAM system, allowing tools to be exchanged as needed during programming.
Another highlight is the intelligent process network within the COSCOM ECO-system. The CAM system enables bidirectional information exchange – even “backwards” if tools were changed during the execution of a CNC program.
Further benefits arise in the programming workflow. The ESPRIT CAD/CAM system can be launched directly from the COSCOM ECO-system together with the associated manufacturing data. When the CAM session ends, all tools used during programming are automatically documented and stored transparently.
Transforming tool data into a process-ready digital twin requires significant expertise. Because interfaces between integration partners evolve over time, this expertise must be maintained continuously.
COSCOM therefore provides professional project management for process integration. Its Dortmund office also hosts a specialized team dedicated to these tasks.
Everything Clean and Organized
Shop floor digitization at BERG has made impressive progress.
More than
- 5,000 items
- 15,000 CNC programs
- over 1,000 digital tool twins
are now managed within the system.
“In the past we sometimes created duplicate tools simply because we lacked an overview – the same tool might exist under two different master data records,” recalls Dirk Deppe. That problem has now been eliminated.
A built-in name generator within the COSCOM ECO-system ensures consistent tool naming conventions. These identifiers are automatically generated and later transferred to the ERP system for storage in the corresponding tables.
Cost Optimization Through Tool Usage Transparency
The data flow from the ERP system to the COSCOM ECO-system is already working smoothly.
“However, we still need to verify whether the reverse data flow works reliably, because significantly more shop floor-relevant data can be generated in COSCOM than in the ERP system,” explains Oliver Oberkoch.
Additional ERP integration is planned via COSCOM warehouse functions. The COSCOM warehouse modules extend ToolDIRECTOR VM and enable direct communication within tool logistics processes. Storage location management, inventory control of tool components and complete tools, and automatic identification of missing parts all contribute to improved tool availability. Connecting these functions to the process-controlling ERP system completes the tool logistics chain.
“ToolDIRECTOR VM provides transparent usage reports,” explains Kolberg. “You can see exactly in which articles, CAM or NC programs, on which machines, and with which tool components specific tools were used.”
This transparency enables detailed evaluations of:
- tool consumption
- procurement planning
- actual process costs
The experience gained from this continuous process knowledge can then be used economically in future production planning.
High Acceptance Among Employees
Oliver Oberkoch is satisfied with the progress achieved so far. “All activities are displayed in a single user interface. Employees no longer have to search for information across five different systems. This has significantly reduced the training effort.”
Initially, some workers were skeptical about the new digital environment. However, this quickly changed.
“Employees soon realized that the COSCOM system actually works very well – even better than the previous solution. Networked information can now be documented directly in the digital information sheet or used during shift handovers, for example to record recurring issues when running CAM programs.”
At a Glance – The COSCOM ECO-system at Berg & Co. GmbH
The tasks:
- New tool management and DNC connectivity following the transition to a modern IT infrastructure
- Paperless information and graphical visualization directly at the machines
- Central database for manufacturing and tool data, including the tool presetting center
- Reliable NC program management with audit-proof change tracking
- Integration with the APplus ERP system
- Standardization of drawing and NC program management
- Reusable and process-reliable machining workflows
The solutions:
- Replacement of legacy interfaces with modern REST-based communication between ERP and satellite systems
- Implementation of ToolDIRECTOR VM for comprehensive tool management
- Modular system architecture enabling scalable digitalization
- FactoryDIRECTOR VM as the central platform on the shop floor
- Single source of truth and digital thread across all connected systems
- Data visualization via InfoPOINT VM directly at the NC machines
BERG, a clamping system manufacturer from Germany, decided to introduce a digital process network with a central COSCOM data platform in order to connect its previously isolated IT solutions in production into a powerful overall system. All production information is now clearly presented via a single user interface. Data from various applications — including the ESPRIT Edge CAD/CAM system and the HAIMER tool presetting device — is consolidated and displayed at a glance in a task-oriented manner. Production data is visualized via COSCOM InfoPOINT terminals located directly next to the turning and milling machining centers.
Reliable, Innovative Pallet Clamping
BERG is known for its low-profile clamping heads and zero-point clamping systems. These systems act as an interface between the machine table and the pallet, making them particularly suitable for automated pallet changing. The aim of these designs is always to generate high holding force with minimal applied force.
The company specializes in the design and high-precision manufacture of modular clamping systems for all standard interfaces used in gear and motor spindles.
Another component of the product portfolio is rotary unions for transferring media such as cooling lubricants, air, or hydraulic oils. BERG’s machine park includes a total of 18 turning and milling centers as well as grinding machines, some of which operate in double shifts and are run by around 30 employees.
A modern building complex houses approximately 5,000 m² of production space. The company is also particularly proud of its extremely low manufacturing tolerances of ±1 µm for four jointly manufactured zero-point clamping systems — a level of precision that is difficult to replicate.
At the Forefront – Also in Terms of Digitalization
The implementation of the COSCOM ECO-system represented a major step for BERG. The previously used DNC service from DLoG could no longer be installed after the transition to modern computer and IT structures. Support had also been discontinued after the supplier was acquired by a larger company.
The previously used tool management system also caused difficulties. A mandatory upgrade from the manufacturer would have been in the same price range as purchasing a completely new system.
“Experience forced us to look for alternatives. That’s when we came across the concept of satellite connections with a central platform and the modular solution offered by COSCOM in Ebersberg near Munich. We quickly realized how much this could move us forward. COSCOM’s promise of long-term support also confirmed that we had made exactly the right decision,” recalls Oliver Oberkoch (CAM programming / production planning).
Dirk Deppe adds:“We knew we were embarking on a longer journey toward digitization and that there would be a lot of work involved. But we were pleased to have a single point of contact.” After all, internal data first had to be harmonized and interface issues clarified with the providers represented within the company. “It would have been extremely difficult for us to handle this on our own,” recalls the member of mechanical manufacturing.
Ingo Kolberg, Senior Sales Manager at COSCOM, also looks back on that time: "On our recommendation, BERG decided not to simply replace one tool management system with another. Instead, we emphasized the advantages of using future-proof processes and data — including production information, machinery, NC programs, tool management, and production-related ERP data — all controlled via a central data platform.” The focus was placed on the complete article reference of the production order, from the NC program through to machining — in other words, the entire process chain. “And what was promised was delivered. Today, everything is clearly structured. For each article, all relevant process information is displayed centrally in a single digital production data sheet,” says Oliver Oberkoch enthusiastically.
Everything Revolves Around the Central COSCOM ECO-system
COSCOM’s new process network connects the internal system landscape with its “satellites” on the shop floor. The central data hub is FactoryDIRECTOR VM (Virtual Machining), where all production information is stored in a structured manner. This includes article master data and work plan data from the ERP system. BERG uses APplus as its leading ERP system. All data and information generated on the shop floor is now assigned to the versioned production item and the corresponding work sequence within the work plan in the central database.
FactoryDIRECTOR VM serves as the operational hub for integrated application systems such as:
- the ESPRIT Edge CAD/CAM system
- virtual machines
- turning and milling machining centers
- the HAIMER tool presetting device
Production data is visualized exactly where it is needed via InfoPOINT VM terminals located close to the machines.
All Together at One Table
Integrating satellite systems cannot be taken for granted. In fact, it requires significant coordination and project management – areas in which COSCOM has built up extensive expertise for more than 40 years. “To ensure that all systems work together smoothly, many different interests must be aligned and coordinated,” explains Ingo Kolberg. The project team therefore included internal project management and shop floor users at BERG as well as system providers such as APplus, Pimpel (ESPRIT CAD/CAM system), and HAIMER Microset (tool presetting device).
Taking the lead in process integration is essential. As Kolberg notes, “many system providers focus on selling their products but do not employ their own process integration specialists.” Numerous satisfied customers and integration partners demonstrate that COSCOM has earned its reputation as a “director” of complex digital production environments.
“Renowned system, tool, and machine manufacturers now approach us to ask how their data should be provided so that it can be optimally used for shop floor digitization. We rely on modern REST services and other contemporary communication technologies to connect these systems effectively,” says Kolberg.
The company also maintains close cooperation with CAD/CAM providers. “Some even have their interfaces certified by us. But we don’t talk to customers about interfaces – we talk about the benefits of integrated processes to achieve their specific digitization goals.”
For BERG, this integration brings clear advantages. Digital twins of tools help optimize setup times and increase tool reuse by providing transparency about which CNC programs previously used a specific tool.
ToolDIRECTOR VM can also communicate directly with the CAM system, allowing tools to be exchanged as needed during programming.
Another highlight is the intelligent process network within the COSCOM ECO-system. The CAM system enables bidirectional information exchange – even “backwards” if tools were changed during the execution of a CNC program.
Further benefits arise in the programming workflow. The ESPRIT CAD/CAM system can be launched directly from the COSCOM ECO-system together with the associated manufacturing data. When the CAM session ends, all tools used during programming are automatically documented and stored transparently.
Transforming tool data into a process-ready digital twin requires significant expertise. Because interfaces between integration partners evolve over time, this expertise must be maintained continuously.
COSCOM therefore provides professional project management for process integration. Its Dortmund office also hosts a specialized team dedicated to these tasks.
Everything Clean and Organized
Shop floor digitization at BERG has made impressive progress.
More than
- 5,000 items
- 15,000 CNC programs
- over 1,000 digital tool twins
are now managed within the system.
“In the past we sometimes created duplicate tools simply because we lacked an overview – the same tool might exist under two different master data records,” recalls Dirk Deppe. That problem has now been eliminated.
A built-in name generator within the COSCOM ECO-system ensures consistent tool naming conventions. These identifiers are automatically generated and later transferred to the ERP system for storage in the corresponding tables.
Cost Optimization Through Tool Usage Transparency
The data flow from the ERP system to the COSCOM ECO-system is already working smoothly.
“However, we still need to verify whether the reverse data flow works reliably, because significantly more shop floor-relevant data can be generated in COSCOM than in the ERP system,” explains Oliver Oberkoch.
Additional ERP integration is planned via COSCOM warehouse functions. The COSCOM warehouse modules extend ToolDIRECTOR VM and enable direct communication within tool logistics processes. Storage location management, inventory control of tool components and complete tools, and automatic identification of missing parts all contribute to improved tool availability. Connecting these functions to the process-controlling ERP system completes the tool logistics chain.
“ToolDIRECTOR VM provides transparent usage reports,” explains Kolberg. “You can see exactly in which articles, CAM or NC programs, on which machines, and with which tool components specific tools were used.”
This transparency enables detailed evaluations of:
- tool consumption
- procurement planning
- actual process costs
The experience gained from this continuous process knowledge can then be used economically in future production planning.
High Acceptance Among Employees
Oliver Oberkoch is satisfied with the progress achieved so far. “All activities are displayed in a single user interface. Employees no longer have to search for information across five different systems. This has significantly reduced the training effort.”
Initially, some workers were skeptical about the new digital environment. However, this quickly changed.
“Employees soon realized that the COSCOM system actually works very well – even better than the previous solution. Networked information can now be documented directly in the digital information sheet or used during shift handovers, for example to record recurring issues when running CAM programs.”
At a Glance – The COSCOM ECO-system at Berg & Co. GmbH
The tasks:
- New tool management and DNC connectivity following the transition to a modern IT infrastructure
- Paperless information and graphical visualization directly at the machines
- Central database for manufacturing and tool data, including the tool presetting center
- Reliable NC program management with audit-proof change tracking
- Integration with the APplus ERP system
- Standardization of drawing and NC program management
- Reusable and process-reliable machining workflows
The solutions:
- Replacement of legacy interfaces with modern REST-based communication between ERP and satellite systems
- Implementation of ToolDIRECTOR VM for comprehensive tool management
- Modular system architecture enabling scalable digitalization
- FactoryDIRECTOR VM as the central platform on the shop floor
- Single source of truth and digital thread across all connected systems
- Data visualization via InfoPOINT VM directly at the NC machines