Manufacturing is used to change: mechanization in the days of steam power, then electrification and later the introduction of CNC. At the same time, increasingly powerful precision tools and materials enriched the industry. Currently, the focus is on 5-axis machining, process integration and automation. Each of these developments was considered revolutionary at the time but developed more as an evolution. The future project "Industry 4.0" is no different. The vision described back in 2011 is basically about implementing holistic transparency from the creation process of products through to their disposal or recycling. The path to digital transformation (DX) now seems to have been paved.

What does digital transparency mean in CNC manufacturing?

With regard to the digital environment of CNC manufacturing, the transparency requirement applies from the receipt of the raw material to the production of the workpieces or assemblies through to their delivery. On the scale of Industry 4.0, companies should be digitally enabled to monitor, analyze, optimize and traceably document their entire processes and workflows digitally and seamlessly. In addition, companies should be able to share their data in digital supply chain and value creation networks in a collaborative and self-determined manner.

On the way to the vision, CNC manufacturers must therefore be able to ensure the seamless networking of all manufacturing processes and systems. Control systems then provide data on the status of machines, workpieces, processes and internal workflows. The digital recording and analysis of this information in turn makes it possible to monitor and optimize the entire production process from end to end. This involves not only machine-specific data, but also information on supply chains, material quality, cycle times and energy consumption. This transparency has several levels:

- Operational transparency: real-time monitoring of production steps, machine statuses and quality indicators.

- Process transparency: Complete traceability of a workpiece from material receipt to delivery.

- Analytical transparency: The ability to collect, analyze and continuously improve production data.

 

The added value of digital transparency in CNC production

Digital transparency provides CNC manufacturing with numerous added values that will be decisive for both large companies and small and medium-sized enterprises (SMEs). Among other things, it will be possible to derive elementary knowledge from real-time data in order to optimize machining processes, increase machine running times, minimize downtimes and idle times and make the production flow more efficient overall. By detecting faults or deviations in the process at an early stage, companies can act proactively instead of reacting to failures or quality problems. This means less waste, less unproductive machine time and greater efficiency in terms of available resources.

Improved quality

Further added value arises for quality assurance, which is of central importance in machining production. Digital transparency ensures that every workpiece is continuously monitored. Machine parameters such as speed, feed rate and tool wear can be automatically adjusted to ensure consistently high quality. In addition, digital documentation allows complete traceability, which is a decisive advantage in the event of complaints or quality inspections.

Faster reaction time

In addition, the entire production process becomes more transparent and therefore easier to control. Delivery delays, bottlenecks or quality defects on the  supplier-side can be identified and rectified in real time. Companies can reduce their stock levels and work just-in-time. This leads to lower costs and companies can react more quickly to market requirements.

Predictive maintenance

Another important aspect is predictive maintenance. By analyzing machine and process data, potential faults can be detected at an early stage. This allows targeted and planned maintenance measures to be carried out before a machine breakdown occurs. This reduces maintenance costs and minimizes production downtimes.

Sustainability and circular economy

Another key strength of digital transparency is the increase in efficiency. Production processes can be planned more precisely and resources can be used in a targeted manner. This applies not only to the use of materials, but also to energy consumption and machine capacity utilization. This allows companies to work sustainably and reduce costs without compromising on quality.

Fit for regulation and the circular economy

Finally, transparency also helps with compliance with legal requirements and in the circular economy. Purchasing departments in many industries are increasingly demanding detailed proof of the origin, processing and quality of materials. With digital transparency, this information can be fully documented and archived. This is not only important in terms of product liability, but also for companies that are active in the circular economy. The digital traceability of workpieces helps to return materials to the production cycle after their life cycle.

Challenges for SMEs

In many small and medium-sized CNC companies, the demands of transparent production can be overwhelming. They lack the necessary investment funds and often the digital expertise to implement modern systems for data acquisition and analysis. However, the gradual entry into the digital transformation is worthwhile.

Starting out with networking individual machines or process steps, companies can gain initial experience and achieve success. It is important to start with a clear goal in mind and not to neglect employee training. After all, the full potential of digital transparency can only be exploited through a combination of technology and expertise.

DMG MORI supports its customers in this process as part of the Machining Transformation (MX) and specifically with the Digital Transformation (DX) products and services. This offers customers a wide range of scalable solutions, ranging from networked machines to digital work preparation and planning, control and management systems through to the future-proof CELOS X platform.

DMG MORI relies on open standards and interoperability to ensure the seamless integration of existing machines and enable step-by-step digitization. The company also supports its customers with targeted training and comprehensive support so that the workforce is involved in the change process right from the start. This enables companies to increase their efficiency, optimize quality and prepare themselves for an increasingly digitized and networked market in the long term.

The future of CNC manufacturing is transparent

Digital transparency is the key to remaining competitive in the age of Industry 4.0. It not only enables higher productivity and improved quality, but also supports more sustainable production. For small and medium-sized enterprises (SMEs) in particular, it is crucial to recognize the right time to tackle the digital transformation. Even though the path to fully connected manufacturing may seem complex, the technological tools are already available. Companies now need to find the courage to integrate these tools into their daily operations and take advantage of the benefits of digital transparency. In the future, it will not only be the precision of production that will determine success, but also the ability to use all data along the value chain intelligently. Digital and transparent CNC manufacturing has only just begun - and it is the future.