For more information about DataXchange machine monitoring or the VERICUT® CNC Machine Connectivity software, visit the SFA booth (#133240) at IMTS 2024

Latest feature to be displayed at the Shop Floor Automations booth at IMTS 2024 in Chicago

Shop Floor Automations (SFA), a manufacturing integrator specializing in digitally transformative hardware, software and support solutions, will demonstrate the new Postcheck feature of the VERICUT® CNC Machine Connectivity software at IMTS 2024 from September 9-14 in Chicago, Illinois. This feature of CNC Machine Connectivity, which utilizes the Scytec DataXchange machine monitoring solution, supports the analysis of digital twin simulations through the replay of stored, live-streamed data from the numerical control (NC) machine. Through such replays, Postcheck allows programmers to retrieve archived data from when a part was machined, then rerun that data in VERICUT® to investigate issues that may have occurred during the machining process.

The VERICUT® CNC Machine Connectivity modules were launched as an add-on to the 9.3 release of VERICUT® software in 2022 through a partnership between CGTech and Scytec Consulting Inc. CNC Machine Connectivity aligns digital twin simulations of CNC programs and live production to enable manufacturers to detect, communicate and validate variances in order to produce higher quality parts at faster rates.

“After verifying NC programs and sending them to the shop floor, NC programmers frequently lose visibility into what happened with those programs in the shop. When asking the machine operator or shop foreman about the performance of the NC programs and any necessary changes, their responses can be too vague at times to identify how or where modifications were needed. This means the same issues will likely occur the next time the programs run,” says CGTech director of product management, Gene Granata. “The Postcheck feature of CNC Machine Connectivity closes the loop on the NC programming process by providing engineers and programmers with access to factually-recorded data about how NC machines and programs ran, including exact spindle or feed rate override percentages or emergency stops that occurred, right at their fingertips.”

VERICUT CNC Machine Connectivity Postcheck

The new Postcheck feature of VERICUT® CNC Machine Connectivity software allows programmers to document and verify actual jobs at any time and location to increase productivity and program accuracy.

As a reseller of DataXchange and various CNC hardware and software solutions, SFA president Greg Mercurio understands the opportunity CNC Machine Connectivity offers those involved with NC manufacturing.

“This latest feature of CNC Machine Connectivity is yet another example of how today’s technology is tightening the processes and relationship between engineering, programming, quality, estimating and the machine shop and tool crib on the floor,” states Mercurio. “We’re excited to share the range of possibilities with manufacturers at this year’s IMTS.”

For more information about DataXchange machine monitoring or the VERICUT® CNC Machine Connectivity software, visit the SFA booth (#133240) at IMTS 2024, call SFA at 619-461-4000 or visit www.shopfloorautomations.com.

Scrap material in manufacturing - Shop Floor Automations

Imagine this: as a manufacturer, one of your engineers or CNC programmers has finally completed a product design for a part worth $75,000. They add the files to a USB thumb drive and run it out to the shop floor to upload the design and work instructions for the second shift. Success, he or she thinks. However, one of your team members made a last-minute change to the files without your knowledge. You won’t find out until the prototype is rejected by the customer, scrapping the part and costing your company thousands of dollars, even more time and effort, further project delays, interdepartmental frustration and a dissatisfied customer. Yikes.

Ideal PDM software ties engineering designs, CNC programs and production documentation for full revision control

In reality, manufacturers today have far greater ability to prevent a scenario like this from occurring in the first place. Modern production data management or product data management (PDM) software solutions are specifically designed to manage your manufacturing documentation, like CNC programs, CMM programs, machine offsets, Standard Operating Procedures (SOPs) and Material Safety Data Sheets (MSDS), to reduce inaccuracies, improve productivity, security and efficiency and speed up time to market. The revision control features of a well-designed PDM, such as Predator PDM, can allow for revisions per vault item, not per file, allowing you to condense the number of files it takes to run your business. New revisions or status changes are validated once-a-minute on every shop floor PC, and the correct program and work instructions may be selected from a pick list tied with the job scheduled in your ERP or MES system – all features to ensure the right CNC production documentation is sent to the right job at the right time.

Proper PDM software aids the CNC program and documentation process on the shop floor for less waste, faster time to market, increased productivity and more.

The use of Windows folders and other alternatives to fulfill regulated traceability requirements often fall short of meeting compliance standards.

Compliance Tracking for CNC Production Documentation

“Manufacturers and their industry partners are becoming greater generators and consumers of data output from their operations, particularly as automation increases,” wrote the National Institute of Standards and Technology (NIST) in late 2023. As regulatory bodies, such as the Food & Drug Administration (FDA), Department of Defense (DoD), and the Federal Aviation Administration (FAA) seek to control this data collection and consumption movement, manufacturers are responsible for tracking, restricting and proving the path of all production documentation. Applying traditional means, like pen and paper, text files or Windows folders, to meet the latest traceability requirements lack the revision control, visibility and reliability to fulfill such mandates. Even USB thumb drive usage can be significantly limited or prohibited altogether in order to achieve compliance. With so much regulation and new technology available now, how does a manufacturer find and implement an optimal PDM solution?

A partnership with a manufacturing integrator with experience in your industry – be it aerospace, defense, oil and gas, medical device and pharmaceuticals or another industrial sector – and a broad software and hardware portfolio can help you better navigate options to institute effective and compliant processes to deliver profitable products. Contact a manufacturing expert at Shop Floor Automations to help reduce time to market, decrease waste and enhance the security of your CNC production documentation by visiting shopfloorautomations.com now.

IMTS 2024 attendees can visit Shop Floor Automations for manufacturing integration solutions and support

“Everything we have today is the result of going to Chicago, walking through those doors of IMTS, and seeing all the amazing technology. It’s a great atmosphere. It’s like walking into a living room that’s set up as a CNC shop with people smiling and ready to help you.” 

 — Ashley Miller, Co-owner, ARC EDM 

For those who attended the International Manufacturing Technology Show (IMTS) 2022, like Miller, they know that there was plenty to keep over 86,000 registrants from 110 countries interested in the 1,816 exhibitors. IMTS 2024 promises much more, with many new product launches and networking connections anticipated over the course of the six-day event.

Visit Shop Floor Automations at IMTS 2024 in Chicago

New Products, New Connections

ZOLLER (booth #432018), for one, plans to introduce its >>coraMeasure LG<< automated tool measurement system to improve tool measurement precision and speed by delivering tools to a linear robot that removes tools from the pallet and moves them to a ZOLLER >>venturion<< presetting and measuring machine. Each tool is identified with the ZOLLER >>dChip<< system and tool data is stored in the ZOLLER z.One database and accessible anywhere.

The new HAIMER (Booth #431510) Automation Cube One will also make its debut at IMTS 2024. This fully automatic robotic cell can shrink fit a tool, measure it and send the data to the machine tool in just 60 seconds. The Automation Cube One features a FANUC cobot for handling of tool assemblies and a Siemens Sinumerik One CNC control.

IMTS machine monitoring exhibitor Shop Floor Automations

DataXchange, available through IMTS machinoe monitoring exhibitor Shop Floor Automations, has released new protocol for supported equipment brands, including Okuma, Heidenhain and Siemens.

For those exploring machine monitoring and data collection solutions, Scytec Consulting (Booth #133240) has released new protocol for machine brands like Okuma, Heidenhain and Siemens to connect more data points for greater depth and analysis of equipment on the shop floor with its DataXchange equipment monitoring software. The added collection of Siemens spindle speed rates, for example, can help identify faults for better finish and surface quality due to consistent cutting speed at the tool cutting edge.

The partnership between Scytec and CGTech’s VERICUT® takes machine monitoring a step further through digital twins to simulate your manufacturing environment and identify the presence of variances before production begins on the floor, thereby minimizing or eliminating non-conformances and rework. Attendees seeking an IMTS machine monitoring exhibitor will have first access to the latest Post Check feature of CNC Machine Connect, in which users may replay stored, live-streamed data from the program for even greater visibility and predictive accuracy of your simulations.

IMTS 2024 attendees can visit Shop Floor Automations for manufacturing integration solutions and support

Greg Mercurio, president of manufacturing integrator Shop Floor Automations, says that “It’s the relationships that we start and build at IMTS that make the show such a vital experience. Not only are we able to demonstrate the latest advances in our technology portfolio, but our deep customer connections allow us to match the right solution and service to their environment so they can focus on their producing high-quality product.”

To plan your IMTS show with these exhibitors and others, visit www.imts.com.

DoD contract manufacturing

In an effort to ensure defense contractors are following best practices to protect sensitive data, Cybersecurity Maturity Model Certification Program (CMMC) rulemaking is inching closer and closer to finalization, with rules proposed by the U.S. Defense Department on December 26, 2023. While these rules are published for comment, the codified version isn’t expected to change too drastically. Townsend Bourne, partner at Sheppard Mullin, noted as much during a recent interview with Federal News Network. “Personally, I don’t know that we’re going to see significant changes from the proposed rule that came out at the end of December and the way the final rule is drafted,” said Bourne. “Most importantly, because DoD has been working on this program for so long, and I think they’re at the point where they think it’s pretty close to final.”

CMMC 2.0 Level 1 Sneak Preview

USB CNC program transfer cybersecurity

Transferring CNC programs via USB can not only require hefty management of manual user authorizations, device logs and documentation, but they can risk USB CNC program transfer attacks and noncompliance with CMMC 2.0.

The progression of this rulemaking process is quickly advancing the impact of CMMC 2.0 to manufacturers of all sizes, especially small-to-medium sized businesses (SMBs) that will need to carefully manage finite resources to absorb added costs, personnel and training to meet and maintain compliance. One aspect of CMMC 2.0 that will deliver a layer of complexity is the proper storage and control of removable media, like USBs and CDs, which many defense contract manufacturers utilize today to transfer CNC programs, images and other Federal Contract Information (FCI) and Controlled Unclassified Information (CUI) to and from computers and machines. Let’s review a few aspects of the Level 1 requirements clause of 52.204-21, Basic Safeguarding of Covered Contractor Information Systems, to illustrate some of the necessary steps to store and control sensitive data appropriately on these devices.

  • Limit information system access to authorized users, processes acting on behalf of authorized users, or devices (including other information systems).

There should be a clear set of procedures regarding who is permitted access to removable media, their accountabilities related to this access, and how often these procedures are reviewed, validated and updated. Programmers, engineers and others involved in the CNC program transfer process should have unique credentials and the correct identity or role-based permissions across devices and systems. Credentials and keys should be properly managed and rotated to enhance the security of sensitive information. If you’re manually managing user security and authorization related to CNC program transfers via paper or spreadsheets, for example, it can be a time-consuming and involved endeavor that may be prone to errors and noncompliance.

  • Limit information system access to the types of transactions and functions that authorized users are permitted to execute.

It’s necessary to have documentation of the transactions roles and personnel are authorized to execute, so that sensitive data is not processed by those lacking permissions to do so. But do you also have the safeguards to block unauthorized transactions and track those attempts? Again, a manual means to meet this requirement can not only be labor-intensive and riddled with inaccuracies, but near impossible for some DoD contract manufacturers with complex operations.

USB CNC program transfer attacks

  • Verify and control/limit connections to and use of external information systems.

Even limiting the use of removable media can still leave data susceptible, as USBs are re-gaining popularity in cyberattacks. Daniel Wiley, the head of threat management at Check Point, relayed an instance in which a power company employee received a sealed USB device from an Amazon package, complete with Amazon tape. “He thought his wife ordered it. So he opened it up, plugged it in. Everything else was a chain reaction. It was able to break in across their VPN. Let’s just say the power company was not in a good place.” It is imperative for defense contractors to have the proper controls set up to protect your CUI against USB CNC program transfer attacks – but no controls will be completely failsafe.

Roll Credits

It’s estimated that a CMMC Level 1 self-assessment will cost a small entity about $6,000, according to DefenseScoop. For SMBs, this cost could be significantly more depending upon the existing IT infrastructure, processes and know-how of your staff. To understand how an ideal DNC software, which is a system that leverages Industrial Internet of Things (IIoT) to connect your shop floor equipment on one network, can help reduce or eliminate manual user authorizations, device logs and documentation for more streamlined CMMC 2.0 compliance and prevention of USB CNC program transfer attacks, contact a representative with manufacturing integrator Shop Floor Automations today.

Predator Software Inc logo, which is a blue gear with a bear pawprint in the center.

PDM, MDC and DNC software are among the highest-sought Predator solutions supported by the manufacturing integrator

Shop Floor Automations (SFA), a manufacturing integrator specializing in digitally transformative hardware, software and support solutions, announces its exclusive achievement as the top reseller of Predator software since 2004. This significant milestone represents the integrator’s deep industry and technical expertise and unwavering commitment to customer success by serving thousands of North American manufacturers of aerospace and defense, automotive, oil and gas, heavy equipment and medical device products.

 

“Predator software is a renowned provider of manufacturing automation solutions and leader in Industry 4.0, Industrial Internet of Things (IIoT), digital factory and lean manufacturing,” says Greg Mercurio, president and founder of SFA. “By coupling these solutions with the excellent service, skillset and knowledge of our technical team, our customers realize tangible gains and have come to rely on us for all their automation needs.”

Engineer working with DNC Software at his desk.

Shop Floor Automations has served manufacturers as their premier Predator Software reseller for 20 years.

 

Robert Jackson, a manufacturing engineer at Flowco Production Solutions, shared his DNC experience in an SFA customer success story.

 

“I’m responsible for helping to design high-quality parts and manage all the planning for manufacturing,” reported Jackson. “Predator DNC gives me the ability to spend my day doing what I’m supposed to be doing.”

 

Today SFA offers the following suite of Predator Software solutions:

 

  1. Predator DNC (Direct Numeric Control) is a robust DNC solution designed to simplify and automate the process of managing CNC programs to ensure secure, reliable and efficient program transfer to CNC machines.
  2. Predator MDC (Machine Data Collection) is an advanced manufacturing data collection system that enables real-time monitoring and analysis of machine performance, production metrics, and downtime, thus empowering manufacturers to optimize processes and maximize productivity.
  3. Predator PDM (Product Data Management) is a comprehensive solution for managing and controlling manufacturing documentation, including CAD/CAM files, setup sheets, work instructions and more, to streamline collaboration, version control, and compliance.
  4. Predator CNC Editor is a powerful editor for CNC program editing, revision control, and backplotting, equipped with features such as syntax highlighting, intelligent search, and customizable templates to simplify programming tasks and ensure code accuracy.
  5. Predator Touch HMI (Human Machine Interface) is designed to enhance operator efficiency and productivity by providing easy access to machine status, job information, and process parameters via touch-enabled interfaces.

 

For more information about SFA and Predator Software to help give your business a competitive edge, call 619-461-4000 or visit www.shopfloorautomations.com.

 

ABOUT SHOP FLOOR AUTOMATIONS

Founded in 1998, Shop Floor Automations (SFA) is a manufacturing integrator specializing in digitally transformative hardware, software and support solutions to increase the productivity, efficiency and profitability of plant facilities throughout North America.

 

Shop Floor Automations has been a trusted reseller of Predator Software for 20 years, and we encourage you to contact our team at any time to find software solutions that give your business a competitive edge. For more information about SFA and Predator Software or to add intelligent automation to your shop floor for better communication, control and improvement, contact Shop Floor Automations at www.shopfloorautomations.com.

operator at cnc control

Your aged CNC machines and legacy Distributed Numerical Control (DNC) software can work fine…until they don’t. Maybe the PC communicating to the machines starts dropping characters while transmitting the NC code, scrapping parts being machined if not caught by the operator. Or the hardware that has been in place for years fails, sending you on a painful and labor-intensive search for a fix. You’re not alone. There’s countless online machine forums in which IT, operations and engineers embark on such a mission to find the right parameters, mappings, connections or other ways to solve their problem stemming from an antiquated setup. This can often be the impetus for Original Equipment Manufacturers (OEMs), contract manufacturers and job shops to start re-evaluating their entire DNC solution.

One professional wrote about their DNC issue on a Practical Machinist forum, “I am trying to set up communication between OKUMA LB15 OSP5000 and a PC…the machine was connected to an ancient PC with old DNC software running on DOS, and it worked fine until the PC had perished.”

The Power of DNC System Integration

But a lot has changed among DNC systems over the past years that can make teams consider upgrading even before reaching a point of failure. Even more so, the integration of modern DNC with other solutions, such as Production Data Management, Manufacturing Data Collection and Touch HMI, can streamline manufacturing data across applications – something legacy DNCs typically cannot support. The benefit of such a proactive approach is often improved CNC workflow efficiency and productivity. Here’s a few recent DNC enhancements that have helped manufacturers realize these benefits by simplifying CNC program management and manufacturing data control.

  1. Wide OS and Database Support: Modern DNC solutions, like Predator DNC, have added support for Windows 2019 Server, including x64 editions, and compatibility with Microsoft SQL Server 2022 and SQL Server 2022 Express. They should also work with Windows 10 and Windows 11 to ensure seamless integration with the latest operating systems and database technologies so you can avoid security risks, elevated IT costs and industry compliance concerns with CMMC 2.0 and other requirements.
  2. Enhanced CNC Equipment Support: Manufacturers migrating to a new DNC or upgrading their current version can take advantage of new protocols for Fanuc Focas and MoriSeiki to facilitate the serial transfer of Cincinnati Press Brake and Punch Press programs, for example, through one central server.
  3. Machine Error Log Centralization: Up-to-date DNC solutions provide access to all command errors in a single machine-specific error log to easily track errors and troubleshoot issues. This consolidation of errors provides transactional visibility across shifts to allow for consistent support on the floor.
  4. Greater Security and Control: For manufacturers in particularly security-sensitive industries, like aerospace, medical and defense, upgrading to a modern DNC solution can enable you to securely access and manage the “EditLock” key switch on a machine tool through the DNC to lock and unlock CNC memory so you can effectively:
    • Control edits of G-code on machine tools
    • Eliminate physical edit keys
    • Report lock, unlock, and sending activity
    • Enable maintenance control with an override switch to disable

At the same time, automatic compression, encryption, and batch file operations features of advanced DNC solutions grant heightened security and control over CNC communication – which is critical when CNC controllers that use outdated Windows OS are left behind when connecting them to the corporate network. A well-designed, secure DNC enables such CNC to remain on the network by installing a small executable on the CNC and bypassing the domain requirements.

  1. An Intuitive User Experience: Modern DNC systems tend to have refreshed user interfaces with color schemes and toolbar buttons that offer an intuitive user experience. Other enhancements, such as improved FTP support, including passive mode and automatic file deletion, simplify the file transfer processes for manufacturers, while comprehensive online help resources give users the self-directed guidance they need to maximize productivity.

The integration potential of modern DNC to other manufacturing applications streamlines data to improve CNC workflow efficiency and productivity, which is something legacy DNCs typically cannot support.

These developments of the latest DNC software can be reason enough to upgrade your existing setup. Through the integration of a modern DNC system with other manufacturing applications under one solution, however, manufacturers can experience even more efficiency and productivity on the floor. Discuss the automation potential of your environment with manufacturing integrator Shop Floor Automations by contacting us today.

Manufacturing Forecasts 2024

As 2023 winds down, it’s an ideal time to consider manufacturing trends and predictions that may affect your goals, plans and budgets for the year ahead.

Overall, there’s an expectation that interest rates will fall in the middle of 2024, fueling more consistent economic growth and acceleration by the end of the year, reports Dodge Construction Network chief economist Richard Branch in Engineering News-Record. Escalating tensions in the Middle East, Russia and Ukraine may present difficulties, however, as will continued labor issues. Alan Beaulieu, president of ITR Economics, recently told the Association for Manufacturing Technology (AMT) that, “The good news is manufacturers will gain economic strength in this country and secure our economic wellbeing for generations to come. But for the individual manufacturer, there will be higher competition for workers in an already labor-scarce market, and that problem will persist for years. The only hope for companies to survive is to drive efficiencies by adopting automation and other advanced technologies.”

CNC Machine Operator worker productivity

Automating for Worker Productivity and Efficiency

For manufacturers feeling the continued pressures of the labor market, they’ve been heeding Beaulieu’s advice and turning toward technology to increase worker productivity while minimizing costs. There’s many examples of this occurring on the shop floor; let’s dive into three:

  1. “I’m trying to upgrade the machines in my shop to a more modern way of communicating with add-ons to keep costs low.” This manufacturer knows it can’t afford to upgrade its machines altogether. DNC software from manufacturing integrator Shop Floor Automations (SFA) was recommended by a user, sharing their experience that “all machines had their serial to WiFi and it was flawless sending from the DNC computer.” That same user leaned on SFA for machine monitoring software as well, noting that management loved knowing when night shift “truly ran great” based on progress reports from the software.
  2. Generative Artificial Intelligence (AI) is everywhere, says Bernard Marr in Forbes. Use cases are often described within enterprise organizations, such as Hitachi’s AI-generated training videos to ramp up new workers in maintenance and manufacturing. But that doesn’t mean small-to-mid-sized manufacturers can’t leverage this technology in 2024. CGTech’s CNC machine simulation solution VERICUT 9.1, for example, uses AI to learn from cutting while simulation occurs to automatically set up tools for optimization and then auto-optimizes NC programs after learning.
  3. From the outset, Cybersecurity Maturity Model Certification (CMMC) compliance would seem to decrease worker productivity as the control of removable media, including PCMCIA cards and USB drives typically used to transfer CNC programs, is significantly tightened, if not prohibited altogether. But for manufacturers still relying on such media, they know the inefficiency – and costs – of uploading programs and getting routers per part. The use of one industrial DNC software network for all your CNC machines, robots, CMMs, PLCs, 3D printers and other equipment can help streamline the CNC program transfer process as well as provide revision control. It’s just in time, too, as CMMC is expected to be included in public contracts sometime in 2024.
manufacturing speed

By partnering with a manufacturing integrator, you’ll be best positioned to address enduring workforce issues at the lightning pace of the modern digital economy.

“The only hope for companies to survive is to drive efficiencies by adopting automation and other advanced technologies.”

While manufacturers look to technology to fill the labor gap and gain a competitive edge in the marketplace, there’s no “one-size-fits-all” solution that will be able to address enduring workforce issues at the lightning pace of the modern digital economy. Only by partnering with a manufacturing integrator that understands your existing environment – and the direction you’re headed toward – will you be best positioned to tackle the trends and predictions awaiting you in 2024. Contact SFA today to discuss your strategic initiatives of tomorrow.

CNC Programmer Transferring Files

PCMCIA card and card readers on aged CNC machines can, inevitably, fail. The reasons can run the gamut: excessive and prolonged exposure to heat, moisture or poor air quality, power surges, improper handling, wear and tear over time, and other factors. Add in the scarcity of viable replacements and, regardless of the cause, the malfunction of PCMCIA cards and card readers can be highly disruptive to your shop floor operations, affecting efficiency, productivity and profitability. There’s two main ways how:

  1. Delays and Downtime. Your cards store critical CNC data like essential programs, instructions and configurations to and from your machinery. If you can’t retrieve or transfer this vital data, at a minimum, you impede the ability to operate efficiently as technicians, engineers and programmers are forced to seek temporary, yet often time-consuming and less reliable, workarounds – thus increasing their workloads and postponing other tasks. You could face essential data loss as historical records and important backups are affected. More significant consequences could impose downtime costs and jeopardize meeting lead times, delivery schedules and customer satisfaction.
  2. Security, Performance and Reliability Risks. If you’re also utilizing PCMCIA cards for software updates, patches or machine maintenance, a reader failure can obstruct your ability to implement necessary improvements or fixes, potentially impacting the overall security, performance and reliability of your equipment.
CNC Programmer Transferring Files

If you can’t retrieve or transfer this vital data, at a minimum, you impede the ability to operate efficiently as programmers are forced to seek temporary, yet often time-consuming and less reliable, workarounds – thus increasing their workload and postponing other tasks.

 

 

From PCMCIA Card Failures to USB Program Transfers

A manufacturer with over 30 machines, including Makino, Matsura, Chiron, Okuma and Kitako, reported having issues loading and unloading programs with the different machine controls through their old laptop. The company brought on a rugged USB Connect unit from manufacturing integrator Shop Floor Automations (SFA) and “the problems have disappeared.” They subsequently purchased another unit for their tooling shop. But for companies changing programs more frequently, the USB Connect series may not be the best alternative option.

PCMCIA cards for CNC program transfers

DNC software, such as Predator DNC, can help manufacturers streamline the CNC program management and transfer process for consistent and efficient results, particularly when involving higher transfer rates and tens of machines. “I’m responsible for helping to design high-quality parts and manage all the planning for manufacturing,” says Flowco Manufacturing Engineer Robert Jackson. “Predator DNC gives me the ability to spend my day doing what I’m supposed to be doing.”

Compliancy Demands DNC Software

For highly-regulated manufacturers adhering to Cybersecurity Maturity Model Certification, or CMMC, DNC software often becomes a necessary option to ensure compliance and reduce cybersecurity risk associated with USB program transfers. But sorting through the best options for your shop floor begins with a consultation with a dedicated manufacturing integrator. To start exploring a modern solution to your PCMCIA card failures, contact SFA today.

Ethernet CNC connectivity

Over the years, Windows-based CNC machines, robots, CMMs, test stands and other manufacturing equipment have proven popular, largely due to their Ethernet-based networking using the corporate network. But as Windows operating systems (OS) reach the end of their lifecycle, Microsoft technical assistance, software updates or security fixes no longer become available. The options, then, for manufacturers needing Ethernet CNC file transfers and running CNCs with Windows 2000, 2003 or older OS are limited: upgrading to a newer Windows OS can be cost prohibitive and involve a lack of support from the equipment manufacturer; or there’s no upgrade path available, thereby necessitating that the whole machine be replaced. 

The IT Imperative

To protect manufacturers from security risks associated with OS lifecycle completions, IT departments have led the initiative to remove older Windows OSs from corporate domains and discontinue support, while eliminating the use of FTP or Windows shares on untrusted VLANs altogether. This movement often relegates manufacturing operations to isolate a PC from the corporate network and go back to manually loading files through portable media – which presents its own set of security risks. TechAdvisory.org reports that 25 percent of malware is spread today through USB devices. Even the United States Computer Emergency Readiness Team (US-CERT) recommends banning portable media devices from the workplace. And for manufacturers subject to CMMC 2.0, the continued use of removeable media devices may involve severe restrictions or nonacceptance altogether.

Manufacturers needing Ethernet CNC file transfers and running CNCs on older Windows operating systems have limited, cost-efficient options. 

All of this leads to a collision course of lost productivity for the shop floor and some major challenges for IT, as programmers struggle to minimize time spent physically transferring files to equipment and maintain accurate version control and IT strives to minimize risk. The good news is that there are other Ethernet CNC file transfer options available than the common scenario above.

Ethernet CNC file transfers

CNC machines running on outdated operating systems lead to a collision course of lost productivity for the shop floor, as programmers struggle to minimize time spent physically transferring files to equipment and maintain accurate version control, and some major challenges for IT as it strives to minimize risk.

Fortified Ethernet Connectivity

A modern DNC networking system, for one, allows manufacturers to still take advantage of Windows 95 and newer OS, Ethernet as well as your existing network infrastructure, all while removing them from your corporate domain and eliminating the use of FTP, unsecure USB, Windows Administrator access and more. This secure version of DNC software, like Predator Secure DNC software, still enables you to transfer your CNC programs, CNC variables, offsets, parameters, PLC registers and other production data to and from your manufacturing equipment – but adds a layer of security with automatic authentication, encryption and data compression.

Machine tools with an RS232 connection, or those with an option for it, can be connected to Predator Secure DNC to avoid connectivity risks. You’ll need knowledge of your CNC machine’s communication parameters, including baud rate, data bits, stop bits and parity settings or the network connection, such as FTP, FileShare, etc. Consult with an expert manufacturing integrator to explore any other prerequisites to connect your CNC machines through a next-generation DNC networking system.

Manufacturing Integrator partnership

One manufacturer with a 20-year-old CNC machine started having issues with its floppy drive corrupting and random file saves not working (and then later working). At the same time, they watched as the supply of floppy drive replacements available through eBay steadily decreased. Another manufacturer couldn’t determine how much time machines were broken down or when certain machines should be replaced over others. “At the same time,” explained their machine process engineer, “we wanted to get a full sense of our capacity.” Yet another manufacturer had problems connecting its HAAS machines to its programming computer with R232 serial cables.

Manufacturing integrator is your link from machinery to operators, IT and engineering

What do all of these manufacturers have in common? They all possessed equipment challenges. And all of those challenges were resolved through their partnership with a connectivity expert: their manufacturing integrator.

The Link Between Your Machinery and Operations

A manufacturing integrator serves as the link between your machinery on the shop floor, internal IT as well as Managed Services IT support and your operators, engineers and programmers. An ideal integrator provides the extensive hardware, software, support and project management options to help keep aging and modern equipment productive, effective and profitable. They’re your single source to troubleshoot issues and roadmap new improvement initiatives.

There are distinctions that make a manufacturing integrator so valuable to today’s shop floors, of course. Here’s four of them:

  1. They’re experts in manufacturing equipment. The team at Shop Floor Automations (SFA), for example, has amassed a combined 100 years in CNC machinery experience. They have deep knowledge across a wide range of machines, which has been collected over 25 years. “The troubleshooting page on HAAS’s website wasn’t even as detailed as these guys [SFA] were,” reported the manufacturer with the R232 serial cabling issues.
  2. They have a wide range of available resources. Whether your existing IT infrastructure requires a LAN Connect device or you want to start capturing machine data to optimize Overall Equipment Effectiveness (OEE), a go-to manufacturing integrator should have the broad portfolio of solutions and support to put you on the right path forward.
  3. They’re time and cost-efficiency focused. Manufacturing integrators are skilled in identifying cost-saving opportunities, whether it’s related to how to phase a machine monitoring or DNC software implementation or the optimal set up time and steps involved with adding USB to CNC machines. And because of their technical expertise, they’re best suited to steer – or troubleshoot directly – issues to the most appropriate team. A manufacturing engineer in the oil and gas industry recalled their IT making changes that caused their DNC software to stop working on 20 machines. After calling SFA support, he was able to have the issue resolved remotely within three hours.
  4. They’re dialed into technological developments. They work closely with software publishers, hardware manufacturers and equipment manufacturers to keep ahead of the latest technological advancements in the industry. These relationships influence the documentation, training, recommendations and best practices that a manufacturing integrator designs to keep your machines profitable.
Manufacturing Integrator partnership

Manufacturing integrators are your single source to troubleshoot issues and roadmap new improvement initiatives.

 

Challenges Resolved

As a result of its collaboration with a professional manufacturing integrator, the manufacturer with floppy drive corruptions was able to swap its floppy drive for a Floppy Drive Emulator to eliminate its data failure and loss risk altogether. The other manufacturer seeking downtime visibility now reveals that, “We no longer rely on anecdotal evidence to understand the effects of machine downtime,” due to its implementation of the Scytec DataXchange machine monitoring solution. The manufacturer with HAAS machine connection troubles? Today its machines are running on the same network as its programming computer – wirelessly.

Learn how you can maximize your partnership with a trusted manufacturing integrator by contacting SFA today.