Is a specialized database application used by the manufacturing industry to reduce production costs by controlling tool usage, inventory, rework and

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Is a specialized database

application used by the

manufacturing industry to reduce

production costs by controlling

tool usage, inventory, rework and

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Reduces production costs by:

• Reducing tool inventory

• Eliminating unknown tool quantities

• Eliminating duplicate tooling

• Eliminating poor tool storage practices

• Reducing crisis tool changes

• Optimizing tool life

• Eliminating unreliable tool data

• Minimizing down time

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Variset 4 -

Comprehensive Tool Management

Features & Capabilities

• Central data repository

• Options and privileges are configurable for multiple security

levels .

• Easy import, export & creation of data

• “At-A-Glance” Inventory management

• Serialization – Auto generate or user specified

• Rework tracking and management

• Tool presetting & gauge interface

• Scheduled & unscheduled tool change register and reports

• Automatically sends e-mail & pager alarms

•Can link to customer’s material requisition software

• Tool costing – Unique to the industry

• Works with bar code equipment & RFID code tags

• Extensive browser based HELP

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Keep Track of All

Scrapped Items

Issue Tooling to the

Factory Floor and

Monitor its Useable

Life.

Total multiple crib

monitoring and

management

Electronically Place

New Orders and Keep

Track of Receives

Alarms

V4

Storage

Place Orders

and Receive

New Items

V4

Factory Floor Tooling

V4

Scrap

Send Components to

Rework and Log

Rework Statistics

Automatically Send

Stock and Tool life

Warnings

Variset 4

’s Process

Rework/Preset

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Variset 4

- Fully Configurable Security Levels

Variset 4 supports multiple languages Users can log onto

specific lines

Security level is based on user name

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Categorized menu bar: All menus are customizable, screens may be locked out at

user/security levels

Large customizable button screen allows

rapid access to screens

Variset 4

- Easy to Navigate Buttons and Menu’s

Create and edit items

Import & export data Gauge tools

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Variset 4

-

Effortlessly Create & Edit Items

Item list

Item

Navigator Search tab can filter items by multiple criteria

Item type drop down list. Choose from Components, Tools, Kits, Containers

or the Variset Tree.

Category drop down list can automatically configure the information tabs for inventory,

rework and tool life tracking Item

information

Search through the plant structure with the Variset

Tree.

Displays the tooling data in a way familiar to plant floor

personnel.

Help Button Function Buttons:

Save, New, Copy, Rename, DeletePrint Button:

Prints all the data for the selected item

Wildcard search field

LineOperation Components in tool assembly Unique location Item number (Kit) Info Customizable item specific fields Tool assemblies in the kit

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Variset 4

–

Add Build-up for Assembly

Associate items together for assemble, disassemble and

inventory transactions.

These are all the components that make up the selected tool

assembly

Double click on a component to access its create/edit

screens. Build-Up

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Variset 4

Supports Multiple Graphic Formats

JPEG GIF CAD _TIF WMF PNG BMP Drawing

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Variset 4

– “

At a Glance” Inventory

Permits Easy Set-up of Inventory Centers

Define and view multiple inventory

locations

Sends high & low stock e-mail and pager alarms

View quantity at a location View total

plant quantity

View high & low stock quantities for each

location Inventory

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Variset 4

-

Calculates Tooling Costs

Tracks tool cost based on a departments actual

consumption.

(Its portion of the tool usage)

Also allows for adjusting costs based on changes in

current pricing.

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Variset 4

Interfaces with Royal and Other

Presetting Gauges

Comprehensive data for proper gauging of tools

Nominal screen categorized and tabbed for easy maintenance of

gauge data Nominal

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Variset 4 –

Gauge Interface

• Full integration with Royal’s presetting gauges

• Full Functionality of the Industry Standard Variset III

• Real time gauging Screen

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Variset 4

-

Complete Inventory Management

Inventory screen menu

Multi-Action

Assemble/Disassemble/Rework: Floor to crib to rework, receive,

scrap & container transactions Rework:

(Cutter grind management) Rework to crib transactions

Scrap:

Removes items from inventory To/From Rework:

Date/Time stamp first in rework Quantity in rework

Selected rework center Score

Increments for priority above Date/Time stamp

Assign item to a person or machine

Component/Container information

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Variset 4

-

“Rework” Inventory Screen

Serialized Components

Color coded for warning and limit levels

Component information

Quickly access additional information or drawings

without leaving the rework screen

Select an option from the drop down list,

“Move” or “Scrap”. Warning and limit levels

to prompt for scrapping of overworked

components.

Serialized tab is only accessible for serialized components

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Number of components being moved

“Move to…” location

Total quantity in rework

Automatically moves containers and all associated

“Tools Not Changed Report”

Shows the top 10 tools that

have not been changed and

graphically displays the top 5

reasons.

“Unscheduled Tool Changed Report”

Shows the top 10 tools that have had

the most unscheduled changes and

graphically displays the top 5

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Variset 4 is configurable for both Comparative or Predictive tool life:

• Comparative:

• Allows for tool change alerts to be signaled

based on reported production counts.

• Maximizes tool life.

• Predictive:

• Allows for tool change to be scheduled based

on reported production counts, expected

future production counts, and the production

schedule.

• Maximizes Production Up-time.

Variset 4

-

“Tool Life” Screens

Items

scheduled for change

Handles tools with multiple edges and varying expected

counts

Unique locations

Change:

Tool has reached its expected life and needs to

be changed Pull:

A different part is to be run on the line. Pull the tool assembly from the unique location and leave

empty. Fit:

A different part is to be run on the line. Fit the tool assembly into the empty unique location

Sends tool change e-mail and pager alarms

Item’s current count

Item’s

predicted count at change time

Accommodates multiple parts machined on the same line.

Prompts personnel to Change/Pull/Fit

• Auto Pilot Feature: (Comparison & Predictive)

• Tool change frequency can be adjusted automatically using

actual tool performance data collected.

• Parameters for adjustment are definable by the user for each

tool.

Changed” reason

Pick the button to process all tools without a “Not Changed”

reason

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Royal’s automatic RF ID tag read/write station

Variset 4

–

Supports Bar Code & RFID Code Tags

Tool holder

Read/Write head:

Read/writes the data to and from Variset 4

Tool holder _{RFID code tag}

(Not visible)

Scan bar codes to

receive, scrap and move

items to and from

inventory centers.

a

Examples of RFID code tag data:

• Tool number

• Tool holder serialized ID

• Preset length (up to 4 edges)

• Preset diameter (up to 4 edges)

• Machine pocket number

• Running totals per cutting edge

• User definable fields

RFID code tag

Read and write RFID code

tags to pass tooling data to

and from CNC machining

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Variset 4

–

RFID Code Tags

In create/edit the tool ID button brings up all the tools with a tool ID micro-chips and selects

proper tool.

On the rework screen the tool ID button brings the

component number

And, brings up the specific serialized component

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Variset 4

–

RF ID Code Tags

Variset 4 does not allow un-maintained components to

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Variset 4

–

Extensive HELP Documentation

“How to” instructions Hyper-linked image

maps to quickly move to the area of

interest Hyper-links to definitions

Help Document contains:

• Hyper-links to related topics

• Content sensitive index and search

• Training with Screen Cam

®

movies

Hyper-links to instructional videos

Content sensitive search

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