Cutting tool makers are already seeing the benefit of lights out manufacturing

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September 2019: Toolmakers have always been subject to technological change. Today the future of tool making innovation goes by many names. The Smart Factory, Lights Out Manufacturing or Industry 4.0. Whatever it is called, there’s one common factor: it’s revolutionary, and is already redefining and optimising the manufacturing processes for cutting tool makers, no matter what size of their business.

Benefits of lights out manufacturing

Reduced wasted materials and time through 3D simulation.
Increased grinding efficiencies through informed, data led decisions.
Accessible for many manufacturers with affordable, easy to program robots.
Possible to achieve 100% tool accuracy through automated in process measurement.

For cutting tool manufacturers this will be a new landscape that places big data analytics and interconnected technology at the heart of daily work. It means streamlined business operations that allows rapid expansion into new and emerging markets and technology throughout the process to remove the need for human intervention.

Change will not happen in one radical moment. For almost 50 years ANCA has been on the journey to help our customers move towards a smart factory solution. Every world-first technology development we’ve introduced, from 3D simulation software to Laser Plus, our in-process measurement system, to RoboTeach, which makes robotic loaders accessible and easy to program, has been iterative change but the impacts will be revolutionary for cutting tool makers.

Cutting tool manufactures are already running lights out

ANCA collaborated with Swiss tool maker Fraisa to develop a customised solution for manufacturing to run 50 hours unattended and grind multiple tap types – reducing production costs by 50%

Amelinda Ilardi, ANCA Engineering Project Manager, facilitated the collaboration with Fraisa. Amelinda said: “To remain competitive in high cost labour markets like Switzerland, Fraisa wanted a machine that could grind multiple tap types unmanned for 50 hours. There was no solution on the market and having collaborated with ANCA in the past, Fraisa approached us to develop the technology they needed.”

“To enable the machine to run unmanned we needed an in-process measurement capability to ensure grinding stability. To do this we designed a new application where the thread pitch diameter is measured by a Renishaw MP250 touch probe. Measuring to ±0.002mm accuracy, this feature is crucial as it ensures every batch of taps are of consistently high quality.”

“Not only can the machine run unmanned for 50 hours, it is fully connected being linked to Fraisa’s factory ERP system for further efficiency and reliable production data gains. The machine can be remotely monitored using our RedaX product and automatically sends notifications to keep Fraisa’s remote staff aware of the machines progress and also any issues or faults that need to be addressed. In addition, RedaX can be used to track the productivity and up-time of multiple ANCA machines.”

Reduced wasted materials and time through 3D simulation
Simulation and 3D modelling tools offer a way for businesses to measure and plan without requiring the use of materials outside the digital environment.

reduces the learning curve for new operators
provides precise design simulation with a full range of compensation and adjustment options
designing the tool digitally achieves significant reductions in tool waste as there is no need to perfect the tool by grinding numerous versions

For example, Scripting, a simple programming language created specifically to automate tasks within ANCA application software, can be used to automate most tool design tasks, such as entering parameter values or drawing line/arc elements in 2D editors. It can also be used to create sophisticated fully-featured custom tool wizards with graphical user interfaces. This means less work for the operator, knowledge retention through capturing design and process intelligence, and reduced programming and set up time.
“In the past the simulation was in my head and that's true of many manual cutter grinders. You have an idea of what you want, and after making the tool you hope it is produced to look like what you’ve been dreaming about. ANCA’s simulation software allows us to create the tool, with all the given parameters and see what the finished tool will look like. That combined with being able to program off machine has revolutionized how we make cutting tools.” Alfred Lyon, Shop Supervisor, AB Tools

Increased grinding efficiencies through informed, data led decisions
Tool manufacturers are applying cloud technology - ANCA’s Management Suite/Redax - to monitor machines and production in real time, allowing

better informed decisions to be made at the time when they will have the most impact
ability to remotely schedule, control and monitor networked machines
factories today can access real-time information, providing enhanced visibility
greater control over manufacturing data.

"With the installation of the Production and machine monitoring software REDAX , we have expanded the possibilities of data analysis more than ever. Thanks to this excellent software, we can track our production planning more accurately. It means we can track the current status and activity of our machines and use the data to plan our production processes.” Tarık Öztürk Production Manager at Turcar
Data analytics are already a core component of many tool manufacturers operations. The use of advanced analytics is being applied end-to-end across the production and supply chain activity. This is

providing valuable insights into areas including production levels,
inventory,
available capacity,
quality levels
order status
to optimise manufacturing processes
predict machine failures before they happen, ensuring production uptime is maximised.

Affordable and easy to use robots and other automation technology enable manufacturing overnight

70% of ANCA customers buying machines with robotic functionality. Far from a nice-to-have add on, CNC machines now come with

operator panels that provide in-built control over both the grinding software and the robotics function
opening the door to greater automation efficiencies.

Tarık continued: “There are a lot of advantages of the RoboMate. The biggest advantage is that instead of a machine standing idle, automation means production can be significantly increased. Process accuracy is another advantage of this technology and the accurate surface finish is why our customers choose to work with us.”
More recent trends are to include dual robots within a single machine - a market first from ANCA - allowing more complex grinding to be completed with ease and improving overall productivity. The primary robot performs principle automation tasks like changing wheel packs, part loading and pallet management, while the second robot can perform a range of functions such as part washing, metrology, part identification and laser etching to enhance flexibility and productivity.
Radio-frequency identification (RFID) technology is used in grinding to increase the flexibility of tool programming, automate the tool loading process and remove the need for operators to program individual loader pallet pockets to a specific tool, enabling businesses to run over night and weekends 'lights out'.

Achieve 100% tool accuracy through automated in process measurement

With increasingly demanding requirements for precision when it comes to tool manufacturing, the challenge has been to grind tools accurately, while still maintaining a high level of productivity and reducing waste. Enter automated measuring solutions that can inspect and measure both in process and offline.
As an example, Zoller measurement technology has been integrated with ANCA software allowing tools to be ground, measured and validated remotely to ensure they are of the right quality to create top-grade parts. The results are automatically sent to the ANCA machine to correct any discovered errors, ensuring 100 precent tool accuracy.

"The ability of the Zoller Genius to network directly into the ANCA machine has helped us be more competitive in the marketplace because we're able to give customers exactly what they're asking for, with diameters down to the millionths and cutting geometries that are plus or minus one degree," Jordan Armitage, Manufacturing Manager at California Tool and Cutter.

In process measurements like ANCA’s LaserPlus, allow the measurement of tool geometries to tolerances of 2 microns or less without removing the tool from the grinder, saving time in the manufacturing process and ensuring maximum accuracy in measurement.

"We have a very strong brand name and we have been making excellent tools since 1996.”says Benchmark Carbide owner Paul St. Louis. ”Our customers are expecting more from us in terms of tolerances than ever before. Automation plus ANCA’s on-machine laser checking system LaserPlus has allowed us to make sure every tool is reproduced to exactly the same specs every time, while operating unattended seven days a week. The better job we do, the more business we can get."