In a modern factory, especially in a factory that has a lot of CNC machines, there are also a lot of different tools, which are often mounted and dismantled on the machines, depending on the needs of the work process. These tools can vary from large to very small, which are easy to lose. And all together, they are all often difficult to locate, that is, their exact location, number and use are kept in the tool data records. Therefore, the flow of data about the tools is integral to success and crucial for good management of the work process with as little downtime as possible. To ensure a seamless process, all systems in planning and on the shop floor must communicate with each other. A uniform database for tools is an essential prerequisite, and Tool Data Management (TDM) with a suitable software-supported system, brings the desired uninterrupted flow of the work process. As far as cost reduction is concerned, if TDM is applied consistently and skillfully, this kind of software tool can bring you up to 20% tooling savings, i.e. the cost per workpiece is reduced by 10% to 20%, while the avoidance of downtime can bring up to 15% more profit to a company that uses TDM software tools.
Why is it important?
Tool data management is required in CNC machine production in order to organise the information about the existing tools in a uniform manner and to integrate it into the environment. The tool data is stored in a database and is recorded and used with the tool data management software. In contrast to a general solution for managing resources, tool management includes specialised technical data fields, graphics and parameters that are required for use in the manufacturing process.
Tools must be in the right place at the right time, and must not be used so much that their useful life has passed and they are worn so much that they will fail during the production process.
Sometimes these cloud-based software solutions are called "tool finder software" and similar names, but in reality many such solutions have been developed and are constantly being improved and upgraded. Their benefit is reflected in the fact that they optimise work processes and bring a more efficient workflow without breaks, bring less downtime for machines that need to work with individual tools, lead to less time for setting up tools on CNC machines, lead to greater transparency and clarity of where which tool is finds and in what usable condition it is, and ultimately, it all leads to savings in money costs and time savings, which translate into money savings. Also, less downtime brings greater machine utilisation.
If the right tool is brought to the CNC machine on time and assembled and put into operation on time, downtimes are avoided, which can, according to Swooshtech research, increase production time and machine utilization even by 30%, which can bring up to 15% more profit to a company that uses TDM software tools.
Last, but not least, is a shorter planning time, i.e. you can see which tool is specifically in a state of wear and tear, and you can order a new one on time, with visibility of the condition of all tools, their exact location in the warehouses, and the calculated time that is needed to get the tool onto the machine. All this cumulatively brings big savings that translate into profits.
Verified Market Research in its research states that “Tool Tracking Software market size was valued at USD 100.5 Billion in 2023 and is projected to reach USD 248.41 Billion by 2030, growing at a CAGR (compound annual growth rate) of 13.8% during the forecast period 2024-2030.”
Also, this is a game-changer in stopping tool loss and tool theft, and accidents in companies using TDM software are also reduced by 40%, Astute Analytica claims in its research.
Is it the right time to implement it?
Most companies using TDM software have seen their production timelines decrease by about 25%, according to Astute Analytica. According to the same source, 50% of improvements in cross-team communication and data availability are achieved by using TDM software, and 60% of companies prefer that data can be accessed via mobile devices (tablets or phones).
An additional 20% is saved on the search for tools and on tool replacement costs (tools are ordered and replaced on time based on data on wear and working hours).
Although RFID readers, scanners, and IoT sensors are elements that require investment, implementation leads to better workflow, lower costs, and the opportunity for SMEs to leapfrog other, larger companies by introducing TDM software, and to achieve improved market positions through implementation. Also, it is important to note that it is not always necessary to implement a new solution, but that it is possible to make improvements to an old, existing solution that no longer works efficiently enough, which saves both time and money (no new systems are bought, but old ones are upgraded).
All this, along with the transparent and efficient collaboration of on-field teams and management teams, brings real financial benefits to the company that adopts or upgrades the existing TDM software, and it is the moment to adopt this software solution - better sooner than later, as with any technological innovation of this magnitude.
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