Real Projects. Real Efficiency.
Learn how I optimize the interface between hardware and software in practice. Anonymized insights into high-impact industrial projects.
Universal Machining Cycles for Aluminum Profiles
The Challenge
For a standard product, multiple individual programs had to be created in the CAD/CAM system for every size variant. This high time effort was not economically viable.
Implementation
Development of flexible machining cycles for variable workpiece lengths, including automatic and variable positioning of clamping devices. Standardization of individual machining steps for maximum modularity.
Result
The operator simply places the profile according to the routing sheet and enters the required finished length in the program header. Workpieces between 500 and 5,500 mm are manufactured without any additional programming.
Freely Configurable SINUMERIK One Gantry Loader
The Challenge
The machine builder had to completely reconfigure and reprogram the gantry loader for every new project. This resulted in valuable time lost during commissioning on site.
Implementation
Development of a freely configurable gantry loader (flexible number of axes and channels) with a standardized interface to various master computer systems.
Result
The machine builder now only needs to configure the control system to fit the actual requirements; PLC programs and NC cycles no longer need adjustment. The system currently covers 22 possible individual configurations.
Quotation Calculation Tool for Contract Manufacturers
The Challenge
A contract manufacturer for CNC milled parts was unable to calculate quotes quickly and reliably. Long processing times led to lost contracts and uncertain customers.
Implementation
Development of a tailored calculation tool that factors in real machine, labor, and overhead costs as well as contribution margins, generating transparent quotes at the touch of a button.
Result
Customers receive reliable quotes in no time. Time-consuming post-calculations are eliminated, allowing saved time to be directed straight into production and quality assurance.
Automated Maintenance Ticketing System
The Challenge
Maintenance operated primarily on ad-hoc requests; work orders (such as machine downtime and maintenance) were hard to track. Actual efficiency remained unclear while operational costs rose uncontrolled.
Implementation
The machine fleet reports faults and manual operator requests fully automatically via OPC UA to the system. Events are immediately categorized and converted into digital tickets. Maintenance staff receive real-time alerts via a web interface or a dedicated Android app. Working hours and spare parts used are recorded directly in the system.
Result
Full transparency regarding costs and utilization, enabling targeted identification and proactive resolution of bottlenecks. An MCP (Model Context Protocol) interface was also implemented to seamlessly automate future AI-driven evaluations.
Condition Monitoring & OEE Optimization
The Challenge
A machine fleet with heterogeneous control generations provided no comparable data. Downtimes were only noticed when they occurred, driving down Overall Equipment Effectiveness (OEE).
Implementation
Implementation of a central data collector via OPC UA. Programming of data blocks in the controls to provide status and piece-count data. Processing of raw data in an SQL database to visualize OEE KPIs.
Result
Real-time transparency across the entire machine fleet. Introduction of preventive maintenance scheduling based on actual operating hours instead of rigid time intervals.
Fully Automated Production Workflow
The Challenge
Orders from an online shop had to be manually translated into production jobs. There was no feedback loop from machines to the sales system regarding production status.
Implementation
Development of a Java middleware that validates incoming orders, checks material availability, and routes jobs directly to the suitable machine. Development of a complementary Android app for operators to monitor progress on mobile devices.
Result
Fully automated chain from customer click to machine start. Massive time savings in production planning and elimination of manual data entry errors.
Automated Clamping Setup Display
The Challenge
Operators selected NC programs without seeing the corresponding clamping setup (e.g., shims and fixtures). Incorrectly loaded workpieces could cause machine collisions.
Implementation
Development of a Java desktop application that reads the program header via OPC UA, detects syntax-coded setup information, and displays the matching PDF document in a viewer.
Result
The operator automatically sees the correct clamping setup upon selecting a program. Machine crashes caused by incorrect setups are prevented, significantly improving operator guidance.
Automated Quality Compensation
The Challenge
Quality assurance measurement results were manually evaluated and compensation values typed into the machine by hand – a time-consuming and error-prone process.
Implementation
Development of a software solution that automatically parses CSV measurement logs, calculates deviations, and generates optimized tool compensation programs for the machine tool.
Result
Implementation of a closed-loop quality process. Scrap rates were reduced, and skilled personnel were relieved from repetitive mathematical tasks.
Shop Floor Data Collection (SFDC) & Time Tracking
The Challenge
Labor and job times were recorded on paper. Accurate cost calculation for complex components was almost impossible.
Implementation
Programming of intuitive machine terminals as well as a mobile Android solution. Employees log into respective jobs via barcode scan or touch interface.
Result
Precise data foundation for job costing. Complete digital transparency regarding the status of all active shop floor orders.
Migration SINUMERIK 840D sl → SINUMERIK One
The Challenge
An existing machine needed to be modernized. This required migrating the control system from SINUMERIK 840D sl to SINUMERIK One while complying with the Machinery Regulation (EU) 2023/1230.
Implementation
Porting existing software to TIA Portal, enhancing manual operation using Create MyHMI /automotive, and securing the OT/IT interface with advanced cybersecurity measures.
Result
The machine operates on a future-proof platform with operator-friendly controls, securely integrated into modern network environments.