Process analysis identities potentials

The extensive re-tooling service from MAPAL now offers data analysis for end users when they set-up the manufacturing process for a new component or when converting existing machine tools for the manufacturing of new components. When optimisation is necessary during running production, MAPAL offers the comprehensive analysis of all the process-relevant data and NC programs using software options that represent a new module in the re-tooling service to identify previously unused data and parameters.

This optimisation data is possible for the machining of one part, several parts or identical machining operations on several machines. The result is that manufacturers can achieve higher part production levels without increasing tool or machine wear.

All the relevant information on process, component, materials, machine and parts produced is collected directly at the manufacturing line with a focus on the individually defined goals. The software collects the data during the running process and this is achieved from communication between the control panel and numerical control unit. No intervention is made in the machine control and this ensures the warranty and service contract for the machine tool and its controller is not affected. 

After the data collection, MAPAL experts analyse all the production and non-production times, paying attention to the spindle speeds, feed rates and current power consumption. The use of every single tool and the corresponding CNC programs is examined, the movements are visualised and corresponding optimisation potentials are identified. It becomes apparent when a tool runs for a period of time without power consumption. In this case, the approach path offers savings potential. The analysis also reveals inconsistent machining operations that could endanger process reliability.

Depending on the customer demands, MAPAL then takes over the CNC optimisation process and transfers the new and improved process to the machine and verifies the reduced program runtimes, the improved component quality and reduced tooling costs. This is all verified with renewed process audits at regular intervals. For more details, contact MAPAL.