Robin Bender cites another significant advantage: the fact that, thanks to digital setup sheets, the data is available in full and immediately. “The entire set of information is available on demand not only at CNC machines but also in other areas, such as tool preparation. This means that staff also benefit from digital setup sheets when setting up and measuring, as well as when assembling complete tooling and clamping fixtures,” he reports, adding: “Digital setup sheets from the ZOLLER TMS Tool Management Solutions software contain all the information and data required to manufacture a component. They are therefore ideally suited to significantly accelerate internal processes—from NC programming to the first machining of a workpiece—and, above all, to make them extremely reliable. Everyone involved always works on the basis of the same, approved data.” 

Always optimally clamped – the Fixtures software module 

Especially for recurring production orders in series manufacturing, it is crucial to provide suitable and tested fixtures quickly and reliably. The Fixtures software module makes a significant contribution to this. Within it, fixtures are each assigned an identification number so they can be precisely identified at any time. All data on specific components, required standard elements (screws, nuts, bolts), and special accessories—such as necessary hand tools—are stored in a single data record. Additionally, further information, such as photos and videos regarding the setup and assembly of the fixtures, can be added. Thus, work planners can access all information required for the correct setup and assembly of clamping fixtures at the touch of a button on terminals. This information is centrally maintained by authorized technical staff. This ensures maximum process reliability, so that the fixtures are always set up in the optimal configuration. In addition, measurement reports, measurement, inspection, and scheduling plans for the repeated measurement, inspection, and calibration of fixtures can be saved and displayed. This ensures that only suitable and approved fixtures are used in production. 

To ensure that fixtures that have been assembled once are available at short notice in the future, the Fixtures software module can be integrated with the sophisticated inventory management system of the ZOLLER TMS Tool Management Solutions software. This allows storage locations for fixtures to be organized and managed just as easily as for tools. 

Short lead times and maximum flexibility are increasingly essential for local manufacturing companies to remain competitive on the global market. However, both can only be achieved in conjunction with reliable processes. Internal processes can be significantly improved, particularly through extensive digitalization. This applies specifically to the transfer of information and data from NC programmers to machine setters, as well as the organization and management of tools, fixtures, and measuring and testing equipment. Christoph Zoller, Managing Director of the family-owned technology company E. ZOLLER GmbH & Co. KG in Pleidelsheim, which specializes in the economical handling of cutting tools, comments: “Digitally transmitted data offers several outstanding advantages. It is usually generated automatically and thus error-free, it is immediately available to all parties involved, and it enables traceable corrections at any time.”

Setting up CNC machines with process reliability 

Above all, the extensive information and data related to NC programs are transferred digitally from NC programmers to machine setters much faster, easier, and more reliably. This applies to the NC programs themselves as well as information on required tools and fixtures, and the materials and dimensions of blanks. Until now, the standard practice has been a collection (folder) of paper forms and data, which is handed out and passed on manually by NC programmers to machine setters. 

To digitize and optimize this process, ZOLLER has integrated the “Manage Setup Sheet” module into its TMS Tool Management Solutions software. The contents of the digital setup sheet can be flexibly customized to meet specific requirements. Thanks to interfaces with 30 different CAD/CAM systems, the setup sheets are largely generated automatically during CAD/CAM programming. NC programmers simply select the CNC machine to be used. The digital setup sheets contain NC programs as well as data on tools, fixtures, and blanks required by the machine set-up technician. As an option, administrative data on main, auxiliary, and setup times can be added. As Robin Bender, Project Manager for the TMS Tool Management Solutions software at ZOLLER, explains, additional information can also be easily integrated into the digital setup sheets. “This includes, for example, comments, drawings, photos, and 3D models of fixtures and clamping setups, as well as videos of complete processes, such as the assembly of clamping fixtures and the clamping of blanks,” he explains. With this detailed information and instructions, the digital setup sheets eliminate time-consuming follow-up questions and tedious searches, for example, for required equipment and auxiliary tools. As a result, they ensure significantly higher process reliability. 

Detailed information on clamping fixtures and tools is included in the respective ZOLLER software modules of the TMS Tool Management Solutions tool organization system. Depending on the configuration level and installation of the entire software, this information can be accessed at the touch of a button to supplement the setup sheet. This ensures that relevant personnel have access to supplementary information as needed. This applies, for example, to the assembly and inspection of clamping devices, as well as the assembly, adjustment, and measurement of complete tooling. Consequently, skilled personnel in work preparation can work much more efficiently and with greater process reliability.