Let's leave the stickers to the children
The time of stickers has expired – at least on the production line. In the world of CNC tool preparation, many still cling to small label tags, even though digital data transfer is not only possible today, but essential for eliminating errors and increasing efficiency.
Little kids just adore stickers! They earn them from the doctor for being brave during their check-up and from the ballet teacher for behaving well in class. You can even bribe them into putting away their toys. And get this – nowadays, you can even print your own stickers at home on special self-adhesive thermal paper. And before you know it, every reachable surface in the house will be completely covered.
It seems this fascination with stickers carries right over into adulthood for many, especially those who work in the tool preparation department for CNC machining. In that environment, they can freely apply a special 'sticker' to every assembled tool – though they prefer to call them 'labels' or 'tags.' They are absolutely convinced that these are an indispensable part of getting their job done. Well, I'm afraid I have some bad news for them: they're not!
Fair enough, they do have some valid points, as it's certainly true that for successful machining, having the right data available at the right time and place is crucial. This data must somehow make its way from where it's created to where it's needed. Lacking a more efficient solution, paper gets the job done, but it's far from efficient. Moving forward, we'll explore in detail how we process and transmit tool geometric data. However, the system we're introducing also offers similar solutions for managing other operational, logistical, and business data across the entire manufacturing process.
Our involvement in the process begins once a request reaches the tool preparation department. Here, components are assembled into the finished tool, which is then measured using a tool presetting device. This is where crucial geometric data is generated. The machine operator must input this data into the machine tool's controller to accurately calculate the cutting edge's precise spatial position for machining. In the traditional, manual approach, an operator visually reads these values from a physical label and then manually types them into the corresponding input fields of the machine's controller. It's easy to see how vulnerable this step is to human error, which can lead to serious consequences such as tool breakage or even machine crashes. Even a single incorrect digit can result in costly damage and extensive production downtime
The aim, therefore, is to remove the human element from this process. While the demand for such automation isn't new, achieving it comes with a host of challenges. Firstly, every single tool needs unique identification and tracking. The values from the presetter then require accurate interpretation and transmission to a central data processing unit. Ultimately, this data must reach the machine in a format the CNC can readily process. Ideally, this entire system should function smoothly, adapting to the wide variety of production equipment and manufacturers found across the plant.
Enter Mcenter, a platform from Siemens' Machinum digitalization portfolio. It includes a powerful software application called Manage MyResources / Tools (MMR /T), specifically designed to track tools throughout their entire lifecycle. This system integrates all IT and Operational Technology (OT) devices across manufacturing into a single, unified network. The goal is to ensure information flows consistently and smoothly during every workflow. At its heart, MMR /T relies on uniquely identifying each tool. This can be achieved using a character string engraved on the tool holder, an embedded RFID chip, or any one- or two-dimensional code. The crucial point is having a compatible reader available at every workstation.
The initial identification happens at the start of the tool's lifecycle: in the tool crib, the holder's ID (e.g., a data matrix) is scanned, and the tool type is assigned. This effectively creates the digital twin of the physical tool within the Mcenter system. Next, the tool is placed into a measuring machine (like a Zoller). Since this machine is also integrated with Mcenter, the measurement task can be immediately initiated by simply selecting it from a list. And this brings us to the crucial moment for achieving paperless operations: the measured values are automatically entered into the system, which then assigns them directly to the tool instance that was just created. The label printer, meanwhile, remains completely idle.
At this point, we have a tool, and our system knows all its data. The only remaining task is to get this information to the CNC machine. Since the machine tools are also integrated with Mcenter, the same system will handle this in the background. When the tool is assembled, it's possible to select which machine requested it. As a result of this assignment, the digital twin of the new tool to be loaded will appear on that machine's interface Once the tool physically arrives at its destination, the machine operator simply scans its identifier. This action automatically loads all relevant data from the server directly into the controller. The operator's only responsibility is to ensure the tool is correctly placed into the tool magazine. Maintaining data consistency is no longer their task.
Once a machining task is complete, or when a tool becomes worn out, it returns to the tool crib. After identification, its next steps are determined. If the tool is still usable, it goes back on the shelf after re-measurement (if necessary). Otherwise, it's disassembled, its digital twin is retired from the Mcenter system, and the holder is then ready to be fitted with a new tool to participate in future production cycles. But that, of course, is another story.
Now that we've followed a tool's lifecycle from assembly to disassembly and seen how operations can function without paper-based data transfer, the question naturally arises: is all this truly worth it? It's undeniable that replacing simple labelling requires a complex system, and its implementation will necessitate transforming existing production processes. However, this simultaneously removes the human factor from the data transfer process. This means that critical settings, which in a worst-case scenario could lead to machine collisions, no longer depend on the machine operator's skill or attentiveness. All of this is just one example among the many functions offered by Mcenter – a development that is not only highly efficient but also visually impressive. The disappearance of physical labels is tangible proof of progress in digitalization, even for those who might work further from the processes happening on the shopfloor.
And even the trees are happy!
At evosoft – as a 100% Siemens subsidiary – we've been involved in the development of this system for over 15 years. Building on the extensive experience we've gained here, for several years now, we've also been offering technical consulting, customization, and commissioning services specifically related to Mcenter.
We currently have an ongoing project at the Budapest factory of a global energy player. Through this collaboration, we are jointly developing the unique details of the solution to address the specific, practical challenges of its implementation.
By the time we're finished, labelling will be a thing of the past there!