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Dallas, USA: Tool life monitoring in a flash

November 2011
25
Author: Robert Auer
Company: E. Zoller GmbH & Co. KG
Dallas, USA: Tool life monitoring in a flash Dallas, USA: Tool life monitoring in a flash - ZOLLER »flash« module keeps track of your tool life

World-Wide-Web, Smartphone, Google, Wikipedia, Wireless LAN [… ]. We are used to ubiquitous information on our mobile devices and PC’s. But if one wants to check tool life or the content of the magazine pockets of a machine on the shop floor it is still the old routine: walk up to the machine and check by punching in a secret combination of keys in the control. For a leading manufacturer in the aerospace industry those time consuming hikes through the shop are now a thing of the past – thanks to the ZOLLER »flash« module.

The ZOLLER »flash« module continuously requests the tool life from the machines. Automatically, in regular intervals and independent of the operator. The current tool status is symbolized by different colors. If the service life of a tool has expired or reached a “warning limit level” it can be released for recommissioning. A picking list for each tool is created by the push of a button. As soon as the tool has been fully commissioned and assembled, it is released for tool presetting. After measure and presetting process the tools are being released for manufacturing and can be used on the shop floor.

In addition to the ZOLLER »flash« module the software module »cetus« can automatically check and calculate the tool-requirement as well as determine which tools have to be changed at the respective machines - based on the actual situation on the machine - this leads to time/cost savings of at least 50%.

At the team meeting everybody agreed. The newly achieved transparency in the entire manufacturing process allows intelligent, pro-active planning. Considering the high number of unplanned tool changes (end of tool life, broken tools) incredible time savings and efficiency gains are possible “by the push of a button”.

The result: ZOLLER tool-life monitoring guarantees minimized downtime and optimized service time – not just in Texas.

Howdy from Dallas, TX
Robert Auer

ZOLLER tool life monitoring »flash«
By using the ZOLLER module »flash« the tool life times per machine are automatically queried in regular intervals (every 30 seconds) independent of the operator. The current tool service life stage is symbolized by different colors. If the service life of a tool has expired or reached warning limit level it is picked out and released for recommissioning.
The tools released for recommissioning are collected in one list. At the push of a button a picking list is created for each tool. As soon as the tool has been fully commissioned and assembled, it is released for tool presetting.

The tools released for tool presetting are collected in a list and can be preset and measured at the push of a button. Afterwards the tools can be used on the shop floor.

Tool exchange list »cetus«
The tool exchange list »cetus« is a software package to calculate the tool requirement as well as to determine the number of tools to be changed at the respective machines.

Check out our new product videos at www.youtube.com/zollertv
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