Universal Cycles for Machining Aluminum Profiles
The Challenge
For a standard product line, multiple individual programs had to be generated in the CAD/CAM system for every single size variation. The high effort and time required could not be economically justified.
Implementation
Development of flexible machining cycles for variable workpiece lengths, including automatic, dynamic positioning of clamping devices. Standardization of individual machining operations to maintain a modular architecture.
Result
The operator simply loads the appropriate profile according to the traveler/work order and enters the target length in the program header. Workpieces ranging from 500 to 5,500 mm are manufactured with zero additional programming effort.
Freely Configurable SINUMERIK One Gantry Loader
The Challenge
The machine builder had to fully reconfigure and reprogram the gantry loader for every new project, resulting in valuable time lost during commissioning within the integrated machine network.
Implementation
Development of a freely configurable gantry loader (variable number of axes and channels) featuring a standardized interface for seamless integration with various MES/host computers.
Result
The machine builder only needs to configure the control system to match actual requirements. The PLC program and NC cycles no longer require manual adjustments. The system currently supports 22 distinct configuration options.
Calculation Tool for Job Shops
The Challenge
A contract manufacturer for CNC milled parts was unable to calculate quotes quickly and reliably. Long turnaround times led to lost bids and uncertain customers.
Implementation
Development of a tailored calculation tool accounting for real machine, labor, and overhead costs as well as contribution margins, generating transparent quotes at the press of a button.
Result
Customers receive binding quotes in no time. Time-consuming post-calculations are eliminated—allowing saved time to flow directly into production and quality control.
Automated Maintenance Ticket System
The Challenge
Maintenance operated mainly on ad-hoc requests; work orders (downtimes and maintenance) were hard to track. Actual efficiency remained unclear while operational costs surged.
Implementation
Machines automatically report faults and operator requests via OPC UA to the system. Events are categorized and converted into digital tickets. Maintenance teams receive real-time alerts via web interface or Android app. Labor time and spare parts are logged directly.
Result
Full transparency regarding costs and machine utilization, plus targeted identification and proactive resolution of bottlenecks. An MCP interface was also integrated for future AI automated analytics.
Predictive Maintenance & OEE Monitoring
The Challenge
A machine park with heterogeneous control systems yielded inconsistent data. Downtimes were noticed only after occurring, hurting Overall Equipment Effectiveness (OEE).
Implementation
Implementation of a central OPC UA data collector. PLC block programming to supply status and part counts. Raw data processing in an SQL database for OEE metric visualization.
Result
Real-time transparency across the entire machine park. Introduced preventive maintenance scheduling based on actual runtime instead of rigid calendar intervals.
Fully Automated Manufacturing Workflow
The Challenge
E-commerce shop orders had to be translated manually into shop floor jobs. No real-time feedback was sent back from the machine to the sales system.
Implementation
Engineered Java middleware validating incoming orders, checking material availability, and dispatching jobs directly to the right machine. Built an Android app for operators to monitor progress on the floor.
Result
Fully automated chain from customer click to machine startup. Massive time savings in production planning and error-free data transfer.
Automated Display of Clamping Setups
The Challenge
When selecting an NC program for execution, operators needed a clear display of the required clamping situation and setup tooling on the machine.
Implementation
Developed a Java desktop app reading the program header via OPC UA, detecting specially formatted syntax, and rendering the corresponding PDF setup sheet in a viewer.
Result
Prevention of machine crashes caused by incorrectly loaded workpieces, alongside seamless operator guidance.
Automated Quality Compensation
The Challenge
QA measurement data was evaluated manually and offset values were typed into machine controls by hand—a time-consuming and error-prone process.
Implementation
Developed software automatically reading CSV measurement logs, calculating deviations, and generating optimized tool offset programs directly for the CNC machine.
Result
Closed-loop quality control implementation. Drastic reduction in scrap rates and relief of skilled personnel from repetitive manual calculations.
MDC Terminals & Time Tracking
The Challenge
Working hours and order times were recorded on paper. Accurate job costing for complex manufactured components was nearly impossible.
Implementation
Programmed intuitive machine-side terminals and a mobile Android app. Operators clock into specific production jobs via barcode scan or touch interface.
Result
Precise data foundation for job costing. Digital real-time visibility into the current progress of all active shop floor orders.