There is a prevailing myth that manufacturers need to purchase brand new machine tools to incorporate into Flexible Manufacturing Systems (FMS). That is untrue. Automating existing machine tools is possible and common. There are ways to navigate through the technical landscape surrounding machine tool interfacing, table or chuck access, safety and more. To help manufacturers, Fastems has published its ‘CNC Automation Guide for Existing Machine Tools.’
According to Fastems, successful shops are defined by their willingness to invest in new technologies. For all but a handful of manufacturers, though, refreshing the collection of machines every few years is just not feasible. Luckily one of the most efficient methods of boosting production doesn’t require the latest equipment. The average non-automated machine cuts only approximately 20% of a full day. Put in the context of an entire year, only about 1,752 hours out of the 8,760 total annual production hours are used. Automation unlocks that wasted 80%.
A rising trend
In practice, existing machine tool automation or ‘EMTA’ can mean automating completely stand-alone machines, machines already integrated into an automation system or a hybrid of the two. In all its forms, EMTA has experienced an increase in demand because automation can boost production and brings opportunities when floor space is limited. In addition, the classic production development parameters around machine tool utilisation rate, lead times, their reliability, profitability, quality, as well as employee engagement are also very important, and a desire to improve in these often drives EMTA.
On top of this, production might be lacking in analytics and KPIs, which are things automation can provide instantaneously. Finally, existing automation hardware can malfunction, or there is a business risk that needs to be solved. In sum, all the so-called traditional benefits of automation are accessible for EMTA cases.
Automation Options
Automation can be divided into the digital and physical. Digital automation encompasses automated production planning and resource management, like Fastems Manufacturing Management software (MMS), a software that automatically optimises workflow by organising labour and materials. Digital automation maximises spindle uptime, minimises scheduling blunders, and provides a current and informed plan for raw materials, tools and machines. Physical automation solutions are hardware setups that can manipulate materials and tools. Pallet systems are designed to move pallets to workstations according to optimised production plans, saving time and labour. Robots can manage the movement of tools for deburring, washing, measuring and marking.
Integrating New Automation with Existing Equipment
Installing automation systems is less about adding new tools, but honing existing tools. The advantage here is that manufacturers won’t have to buy new machines, especially when budget or floor space is a limiting factor. To integrate seamlessly, though, companies should take an intelligent approach to project management, interface selection, interface development and making physical changes to current machines. Failing to make a successful integration could result in manufacturing planning software that offers inaccurate data, robots that mishandle their loads, or simply a general decrease in throughput. The Guide details all the key aspects of automating existing machine tools, including project management, interface selection, and making physical changes to machines.