Switzerland: Unmanned production through process monitoring

Variation in the process can be detected immediately

The CTM system logs the entire process and creates appropriate curve diagrams via its statistics function. The data can be stored on the Artis Terminal (Windows) or in the network. The system basically "learns" the ideal process for each workpiece and processing step. Later variations (process anomalies) can be detected immediately at every moment of the process. Standard monitoring methods are breakage, lack, overload and tool wear, for which alarm and notification limits are individually set and parameterised. The monitoring works reliably from the first go. CTM's self-adjusting system (SAS) with self-calibrating segmentation and adjustment responds automatically to process variations, thus greatly simplifying settings and interventions.

"We notice any changes in the process immediately", says P. Heinemann. Not only potential tool breakage, but also tool wear can be identified. To achieve this, a trend in the development of the processes' total force is observed over a period of time. As soon as a set limit is reached, the process is either switched to a spare tool or another response is initiated depending on manufacturing strategy. Bär und Mettler for example do not use spare tools because of their small lot sizes.

"The global service network Marposs offers supports their clients’ monitoring: In case of questions, Marposs service staff can log into the Windows-based system via Team Viewer. The investment cost for an Artis-CTM system is about two or three percent of the machine tool’s total costs."

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Minimum 130 spindle hours per week

The manufacture of modular tool systems requires a high degree of flexibility. Lot sizes are usually between 20 and 500 pieces. "We want to achieve at least 130 spindle hours per week", says P. Heinemann. This requires a 24/7 production, where only one shift is manned. P Heinemann adds: "At the moment, we are at almost 115 hours. Machine- and system-wise, we already meet the requirements for a higher number of spindle hours, but we have only installed the systems in early 2015 and now the proper planning is crucial."

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