The Tool Management Infrastructure

Whenever a tool management system has been developed, an organized and well-planned tool preparation facility is vital to prepare the specific tooling requirements – off-line, so that tooling might be:

• Built to pre-defined assemblies – from a range of standardized stocked parts, or from tool modules.

• Replacing worn cutting inserts on used tooling assemblies – these tools being returned for rebuilding, or servicing.

• Measuring tool offsets – then, when it is both timely and appropriate, sending tooling in the form of tool-kits to specified machine tools.

• Inspecting tooling – normally undertaken on tool pre-setters and by visual means, to ensure that they are fit for immediate use.

• Assembling: tooling, fixtures, gauges, etc., as a ‘complete tool-kit’ – to be issued to the appropriate machine tool at the correct time.

In order to ensure that consistent and accurate tool preparation occurs, a documented ‘historical procedure’ covering all tooling-related aspects, is necessary, such as: tool inspection, servicing and building, is required for each tool. These fac-tors can be controlled by utilizing a computerized tool management system, as only the data files will need to be updated, together with tooling assembly instructions, with both servicing and inspection being undertaken by a step-by-step approach – if needed. Many of the more sophisticated tool management systems currently avail-able, offer a link back to the original Computer-aided Design (CAD) software, al-lowing tools to be shown graphically assembled as tool parts.

As the these tools travel around the machining facility, through various stages of preparation and measurement, then assembled as ‘qualified tool-kits’

visiting machine tools and then travelling back to the tool preparation area for re-servicing, each stage of the tool-kit’s cycle must be controlled. Information concerning the tool kit’s progress, must be available at any instant and, a means of exercising control is to link each tooling station to a central computer via a DNC-link. As the unique data referring to any tool is stored within the central computer, its identity can be accessed allowing its ‘logistical progress’²¹ to be precisely tracked within the manufacturing facility. For some companies that are unable to justify such a complex tool management method of tooling control, then a much less costly and simpler ‘manual system’ using either printed labels, or bar-codes can be deployed for tool identification when delivering tooling to-and-from the required machine tool. A cautionary note concerning the use of paper labels for tool identification, is that they can more easily become detached during the machining cycle.

In an automated machining environment, there is no real alternative but to have a ‘tooling requirement’ and in particular, employing some form of ‘intelli-gent/tagged’ tooling, typically via permanent machine-readable tool identifica-tion. Such tool identification techniques, allow the necessary data to be interro-gated and retrieved from critical areas around the production facility: machine tools, preparation area and storage, plus other peripheral areas – as required.

Tooling equipped with ‘intelligent’ memory circuits embedded within them (i.e. typically shown in the case of the non-rotating ‘Block tooling’ in: Figures 3.1, 3.2), can automatically perform the functions of: tool identification, tool offsets and cutting data up-dating on the machine tool. Other information

21 ‘Logistical information and knowledge’, in any production environment is vital and has been defined (i.e. by the Council of Logistics Management – CLM), in the following manner: Logistics is the process of planning, implementing and controlling the efficient, cost-effective flow and storage of: raw material, in-process inventory, finished goods and related information, from point of origin to point of consumption for the purpose of conforming to customer requirements.’

ing the tooling data-base pertaining to tool servicing needs can also be exploited by using these ‘tool-coded data chips’, which are securely situated within the

‘front-end’ of each tool.

So that ‘complete tooling control’ is maintained over all the items neces-sary relating to tool-kits, it is possible to extend stock control over all the tooling requirements out on the shop floor (Figure 6.3). Such tool-tracking is important and certain logistical questions must be known, such as: what tooling is where, is it timed to be there now and, what is its present condition, together with other specific questions, which need to be addressed, indicating the complex task of monitoring all tooling, via a computerized tool management system (Figure 6.4).

Tool control software enables these physical transactions associated with the:

tooling, servicing, kitting, recalibration, etc., to be achieved, without loosing track of any individual tool items. The tooling software will also continuously monitor stock levels, allowing replenishments be actioned, once any itemized tool stock level falls below a certain pres-set value.

Fig. 6.3. Tooling and fixturing must be precisely controlled at the ‘focal-point’

of kit build-up/replenishment – at the tool preparation area

Fig. 6.4. Efficient tool management of tool kits around the manufacturing facility, requires some form of ‘tool tracking and identification’ – as ‘kits’ are: serviced and built, measured,

the sent to an awaiting machine tool

Note: Courtesy of Sandvik Coromant.

Obviously, it is important to create a suitable tool management system, that can operate successfully in a company’s machine shop and it needs to be customized to suit their particular tooling requirements from a relevant database.

These tooling-related matters will form the basis for a discussion in the follow-ing section.

6.2. CREATING A TOOL MANAGEMENT