Online networking helps toolmaker

Assembly Automation

ISSN: 0144-5154

Article publication date: 1 March 2003

87

Keywords

Citation

(2003), "Online networking helps toolmaker", Assembly Automation, Vol. 23 No. 1. https://doi.org/10.1108/aa.2003.03323aaf.006

Publisher

:

Emerald Group Publishing Limited

Copyright © 2003, MCB UP Limited


Online networking helps toolmaker

Online networking helps toolmaker

Keywords: Tooling, EDM

Machine utilisation has been increased by 40 per cent following completion of a £400,000 project to introduce process automation with online networking at Mason Pinder Toolmakers of Doncaster.

Mason Pinder, one of the leading toolmakers for the plastics moulding industry, started the project early in 2001, working with Zwicker Systems gmbh. The initial project covered all aspects of electrode production for EDM, and included a chip identification system for each electrode so that progress could be tracked in all process operations (Plate 4).

Plate 4 Part of the tool design facility that runs Cimatron E CAD/CAM

Whilst the EDM process represents a high proportion of total toolmaking costs, Mason Pinder has also seen significant benefits in achieving major gains in total cycle time for manufacture of complex plastics mould tools, up to 25 tons in weight.

"Another advantage of this important innovation is flexibility", says Mason Pinder Technical Director Ken Barrass. For example, we can reprogramme production very rapidly to take account of customer needs, and can now incorporate the impact of tool modifications within hours, rather than days. The project gives our production team full access to online data, enabling complete process monitoring and control.

As part of the project, Mason Pinder has now linked a total of 17 machines, covering CNC milling, wire erosion and EDM, including 2,550 robots for use in the electrode manufacturing cell. All are served with production data from a control centre hosted on a central server linked to Mason Pinder's CAD/CAM facility which operates using Cimatron E CAD/CAM software. This arrangement, runrang Zwicker Systems' automation software, converts all data to a neutral format, saves the process instructions for each machine, and makes information available online throughout the manufacturing process chain. This, in turn, avoids reprogramming, gives an overview of work history on any part or electrode being produced, and allows all reaction times to be shortened significantly.

The automation of electrode production for cavity die sinking EDM as part of the full process is very important. Automation of electrode production, including automatic electrode changes on spark erosion machines, combined with chip identification of electrodes and other work-pieces virtually eliminates process or operator error. The system incorporates a hand-held computer to integrate each chip, and enables workflow history and manufacturing data to be automatically available at any stage in the process.

The successful implementation of this first phase of process automation paved the way for Mason Pinder to extend the system to the complete manufacturing process, and Mason Pinder expects to continue step by step implementation in other areas, such as assembly.

"This new system has transformed our production process", says Ken Barrass. "We can now not only produce all our electrodes on a production line basis, even though most specific electrodes are "one-off", but also monitor parts through the steel milling areas. This gives us much better control of costs, enables us to speed up the complete design to delivery cycle, and has given us a major gain in production flexibility."

For more information, contact: Ken Barrass, Mason Pinder Toolmakers Ltd, Coulman Street Industrial Estate, Thorne, Doncaster DN8 5JS, UK. Tel: 01405 814778; Fax: 01405 814977; Web site: www.masonpinder.co.uk

Related articles