1st Misconception: Our tool data is stored in extensive Excel spreadsheets. We can’t possibly enter all that data manually into a tool management system.

ZOLLER Solution: With ZOLLER, there is no need to manually enter Excel data. The import filter in the ZOLLER software handles the import quickly and easily. ZOLLER imported Excel data for 140 tools into the z.One tool database for a customer in no time at all.

The data transfer from Excel is almost complete on its own. With the data transfer, you’ve already taken the first step toward digital tool management. After that, every machine operator uses this central database whenever they want to use a tool. He or she can access all information regarding tool type, tool holders, extensions, and target and actual data via the database. Setup sheets are also created using the tool database.

2nd Misconception: For us, as a small manufacturing operation, digital inventory management is pointless. We already know where our tools are.

ZOLLER Solution: Everyone knows how frustrating it can be to search for a tool or component. The next job is waiting, time is running out, and stress levels are rising. For one customer, ZOLLER has set up the storage location management system so that a tool’s storage location is automatically indicated on the setup sheets. This ensures that tool preparation runs smoothly.

In inventory management, tool data is supplemented with location information. The software knows what is located where and makes this information available to every employee with a single click. This means less stress and greater process reliability in work planning. Even small manufacturing operations benefit from this.

ZOLLER also offers a fixture management system, which makes it easy to see which fixture belongs to which component, which mounting is required for what purpose, and where everything is located. Measuring equipment, tools, and accessories can also be organized digitally with ZOLLER.

These features can be expanded to include fully digitized tool management in tool cabinets with software integration. At ZOLLER, these storage systems are called Smart Cabinets. When combined with ZOLLER’s TMS Tool Management Solutions software, it enables any manufacturing facility to create a digital representation of its tool inventory, giving you full transparency into storage locations, tool turnover, and inventory levels.

Planning and switching to digital tool management is a breeze with the right storage location templates. And it doesn’t matter which storage system you use in your production facility. Every company should implement digital warehouse management. The effort involved is manageable. At the very least, when you are seeking certification, digitization becomes indispensable.

3rd Misconception: There’s no need to transfer tool data digitally. Our machine operators are so experienced – they’ve always entered all the data by hand.

ZOLLER Solution: Entering all tool data manually into the CNC machine every time is not time-efficient – not to mention the risk of a transposed digit creeping in. With »zidCode«, data transfer is fast and error-free. This ZOLLER solution automatically transfers relevant tool data to the control system of the CNC machine.

Digital solutions provide real relief, especially for routine tasks like entering numbers into machines. »zidCode«, the plug and-play application for tool identification, handles tool data transfer to the CNC machine automatically and without errors.

With »zidCode«, each tool is assigned a unique tool ID. After the measurement process on the tool presetting and measuring device, a printer prints the data as a code onto a label. The machine operator then attaches this label to the tool.

To transfer the tool data to the CNC machine without errors, simply scan the code using the »zidCode« handheld scanner. If a network is available, »zidCode 4.0« comes into play. You scan the tool ID on the CNC machine – for example, using the ZOLLER »idChip« on the tool holder, which uniquely identifies the tool. The corresponding data is retrieved from the z.One database and transferred to the machine control system, minimizing errors and creating greater cost efficiency.

4th Misconception: Tracking downtime? It’s not worth it. For us as a small business, it’s far too time-consuming to track, record, read, and analyze downtime. The effort is completely out of proportion to the benefits.

ZOLLER Solution: Tool life data is valuable for production and cost planning. With the »flash« software, you can immediately see how much tool life is left on your tools. This allows you to optimize tool changes and reduce costly machine downtime.

ZOLLER’s »flash« stores the specified tool life during the first measurement of a tool on the ZOLLER tool presetting and measuring machine, so tool life an integral part of the tool record. 

»flash« then uses this data and monitors the changes in service life during the production run. The remaining tool life is displayed on a monitor in the toolroom using a traffic-light system. You can always see which tool needs to be replaced and when, helping you reduce machine downtime.

Since »flash« tracks all remaining tool life, you can select the tools whose remaining life best matches the next production run when picking parts for an order. 

In addition, »flash« helps you with cost calculations. If tools wear out more quickly on certain materials, »flash« provides you with the average tool life you can expect. This gives you a reliable basis to assess the cost-effectiveness of your calculations.

5th Misconception: There are ten of us, so no one can take care of the network. Besides, we don’t know anything about it.

Digitalization requires networking, but that can bring up valid questions like: “What if the network goes down? Then everything comes to a standstill.” 

ZOLLER offers effective, affordable, and secure solutions that are reliable and easy to manage. With ZOLLER, you can set up a separate network for manufacturing, providing a clear and secure setup that is isolated from the internet. A MSQL server serves as the foundation, and the software required is free.

Both setup and administration are manageable for small-scale manufacturing operations. The ZOLLER TMS Tool Management Solutions software runs on the MSQL server and handles the networking of the machines. ZOLLER has extensive experience with these processes, so when customers consult with ZOLLER before launching their digitization project, they receive the perfect solution right from the start.

Digitalization doesn’t mean you have to do everything at once. ZOLLER takes a modular approach with packages and expansion stages. This allows even small businesses to develop and expand their digitalized manufacturing step by step, in line with their needs.

When we examine common misconceptions about digitalization in manufacturing, it becomes clear that digitalization has a positive impact even on small businesses – through significant cost savings, enhanced security, and increased productivity. 

Today, digitalization is no longer an option, but rather a necessity for staying competitive. ZOLLER is a pioneer in the digitalization of processes related to cutting tools. We are happy to guide you into the digital future with solutions that are proven in practice and easily integrated. They work just as well in small businesses as they do in Industry 4.0 companies. Get more out of your manufacturing.