Executive summary

A global American company with subsidiaries in India used a MAZAK CNC machine to produce four to five different parts, which required operators to manually select the correct NC program specific to that part. To minimize setup times and reduce the risk of human error, the client and MAZAK approached ZOLLER to find a reliable solution that could maintain process security by automatically selecting the correct NC program. After several test runs, ZOLLER successfully implemented »zidCode« to make the customer’s machining process faster and more accurate.
 

Human error creates downtime and mistakes in machining

The company specializes in industrial machinery and was mass producing four to five different parts using a MAZAK CNC machine. Each part required its own dedicated NC program, and machine operators had to manually select the correct program whenever a part was changed. This process took significant time during machine setup and was prone to mistakes, which could compromise the final product. When operators loaded the wrong NC program, there was risk of machining errors — including rejected parts — or even machine damage.
 

Searching for a solution

With those challenges in mind, MAZAK and the customer began looking for a reliable solution that would automatically select the correct NC program based on the part. The solution needed to eliminate manual intervention to reduce dependency on operator experience and reliably prevent selection errors that caused rejected parts. 

MAZAK approached its technology partner ZOLLER with the challenge. After technical coordination, ZOLLER proposed that the client use its »zidCode« system to identify parts and automatically select the corresponding NC program on the control system. This was determined to be technically feasible after an initial functional test with a single part at MAZAK’s technology center, but problems emerged during the on-site implementation. Each part had its own unique QR code, but only the first eight digits of the code were relevant for identification — a direct mapping of the full QR code to the NC program was not possible. 

Implementing automatic data transfer and selection

After several test runs and analyses, an effective strategy was developed. NC programs were assigned based on the first eight digits of the QR code, which served as a common identifier for part groups. Using this identifier, »zidCode« could automatically select the correct NC program on the CNC control with keyboard simulation. It eliminated manual program selection completely, preventing associated errors from incorrect program selection like rejected parts or damaged machinery.

Streamlining parts machining

By implementing »zidCode«, the customer achieved:

• Faster setup and changeover processes 
• Increased machining process reliability and security
• Reduced dependency on operator knowledge 
• A scalable solution for future part variants