THE CHALLENGE
A metal processing plant required manual machine programming to operate its factory equipment due to limited controller capacity.
1000+ memorized programs
Large scale plants manufacture more than a thousand components. This requires programs of drawings to be fed to CNC machines.
Limited memory capacities
The controllers that run the CNC machines have limited memory capacity that can only store 8-10 programs at a time. Factory operators must delete and feed new programs manually at intervals leading to downtime of the machines.
Human factors
The reliance on manual programming leads to errors and human fatigue.
Transformation Strategy
Remote connectivity
Integration of server technology to store a large number of programs that can be accessed from the controller terminal.
Digitalization
All drawings were digitalized to programmable machine language as a step towards paperless technology.
Human-machine collaboration
Human operators were freed from performing repetitive manual programming. One-click access was provided to select programs for each product.
Solution Impact
Reduced down-time of machine
Increased productivity
Reduced product rejection
Improved production flexibility
Cost saving