Making CNC grinding machines smart factory ready

February 8, 2020 1:58 pm

Shifting towards smart factories does not mean scrapping the existing CNC grinding machines and having to invest in a whole new set of machinery. Here we take a look at what it means for CNC grinding machines to become smart factory ready.

Smart factories are becoming the norm of the day in manufacturing, and companies are moving towards this space to improve their operational productivity and performance and stay ahead of the competition. But being smart factory ready does not involve completely revamping the existing technology in favour of modern, advanced equipment. It simply means upgrading some of the technology and changing the way the company thinks about how it operates.

Lucas Hale, Global Marketing Manager at ANCA CNC Machines, which is a company that provides practical, working solutions to extend unattended production, improve quality and ultimately deliver improved returns for increased bottom line profit, talks about how to go about this process.

Change the way you think about tool manufacturing
In the factory of the future, running a factory won’t require a company to be as hands-on with what it produces anymore. Instead of a manual production line, it will have an integrated network of machines that is more efficient in manufacturing processes, intellectual property generation, tool design, customer responsiveness, cycle time, profitability… and the list goes on. Across the company’s business, automated machines will take care of the more laborious tasks before work begins.

With a bit of investment to upgrade your existing technology and facilities, you can reap the benefits of automation easily. Your team will be able to programme machines ahead of time, so that they are able to do what needs to be done throughout the day. And not only will your CNC machines manage the production, but they will also collect and analyse data and make automatic adjustments to production in real time to improve the way you’re running.

CNC grinding machines only need to be connected
While the company will be able to make use of existing CNC machines, it will also have to embrace new technology. To work effectively with other machines and maximise the benefits of a smart factory, each CNC grinding machine will need to be connected to a communication network.

Having a machine connected to a network may seem daunting, but the benefits are unparalleled. The CNC machine becomes part of a smart, connected set of tools working together to make work easier. Depending on the age of the machine, the company can connect machines using either Wi-Fi (the best option to avoid messy cabling) or a cabled LAN connection. While newer machines are Wi-Fi-enabled, older machines can be retrofitted with a Wi-Fi adaptor and software drivers. Check with your vendor first to make sure the driver software is supported.

Exploit your niche, finesse your offering and charge accordingly
As a small company, you’re able to offer a personalised service bigger business can’t. You understand your customers’ needs. You sell the precise product they need to keep their operation running. They need you as much as you need them. So, being small can be your greatest selling point. You can adapt to the market as it changes and respond to demand. Where potential customers may be frustrated by businesses with long lead times, you have the ability to turn things around quickly and with more flexibility. Customers wanting something you don’t manufacture yet can even be an advantage. With the tools and flexibility to make it happen, you can easily expand your offerings and show them how well you understand your niche.

This kind of specialisation is hugely valuable to a business. You’re not only providing labour and materials but access to years of knowledge and refinement. It’s been shown that customers will pay more for specialised products that offer this level of added value.

Embrace automation
Most CNC machines, including those that ANCA produces, already come equipped with comprehensive, advanced software that allows flexibility in everything, from configuring set-up to adaptive processes like product gauging and automatic compensations, thereby freeing your team to work on more valuable tasks. By creating automated systems and processes, you’ll immediately have access to more information than ever before, and this is a huge benefit for you and your customers. Your machines will be able to alert you when you’re running low on materials. They will predict maintenance that’s required to keep them operating, so you avoid lengthy and expensive disruptions.

Better still, they can become part of a wider network of machines. Integrating with other factories will reinvent your supply chain process. Suddenly, your factory can integrate with your customers and your machines can speak to one another. Is your customer running out of a product you manufacture? The machine at your end can find out and start the production process without any intervention from you.

Move forward one step at a time
Don’t worry; you don’t need to do all of this at once and there are easy ways to add automation functionality:

• Add after-market software or hardware accessories, such as lasers to measure tools in production and make sure they’re meeting required design and tolerances.
• Retrofit with automation; robotic loaders mean lower costs and greater volumes. You can have a new robotic loader at a reasonable price installed into your machine to achieve the benefits of lights out or unattended machine production.
• Enable machine connectivity on older machines through a Wi-Fi adaptor and software drivers to connect machines to each other and the wider factory.
• Store tool files centrally with tools and wheel servers. Maintaining a database of each tool file that a machine can use for set-up is a great place to start with software. Your factory can store a whole range of files centrally, so each machine can access what it needs to get the process going.

Planning ahead for future success
This might be brand new for your factory, and there are tricks you will need to learn. For example, did you know that if you’re moving jobs between machines, you will need to have the same version of software on each? And again this is an investment, but the efficiencies will weigh out the costs in a few months; it is about knowing what will be required to make your factory smart.

If scaled manufacturing is not your background, you might need more information before you scope out your strategy. ANCA can help you understand your specific requirements and also help you understand how to incorporate them into your supply chain. Whatever approach you take, you will need to invest in some degree of technology to keep your machines up-to-date and your operation functioning effectively. Without this, other companies will move ahead of you as they can produce more complex tools more efficiently. There are many ways to bring your CNC grinding machines up to speed for your smart factory. The most important thing is that you start.

For more information, visit:
https://machines.anca.com/