Prep tips to ensure your onsite manufacturing integrator service doesn't cause delays.

How to Avoid Costly Delays During Onsite Manufacturing Integrator Service

Save Thousands with Quick Installations for Faster ROI

 

Picture this: The manufacturing integration technician arrives, ready to install your long-awaited machine monitoring, PDM software or DNC software. But within the first 10 minutes, there’s a problem—there’s no login credentials available and your IT staff is occupied with another project. You put in a support ticket to your Managed Services Provider (MSP). The technician waits. Then waits some more. You also learn the IP address that was previously provided are not configured for the proper VLAN. Before you know it, the billable hours are stacking up.

Sound familiar? Hopefully not.

Implementing shop floor software and hardware solutions, especially as part of a connectivity and automation strategy in partnership with your trusted manufacturing integrator, can transform your shop floor’s efficiency—but only if the setup goes smoothly. Every unnecessary holdup adds extra costs of delay, eating into your budget, productivity and ROI realization.

The Costs of Poor Planning

If the technician has to wait for network access, firewall changes or machine availability, you’re paying them to stand around. Your internal team may need to drop other priorities to troubleshoot issues, creating a ripple effect on other projects and avoidable stress and frustration. If delays force a technician to leave and return later, additional travel time and service charges may apply, and tight schedules may push installations even further out. A longer implementation of your software defers its benefits, like potential improvements to efficiency, Overall Equipment Effectiveness (OEE) and downtime, and produces hardware and software licensing waste. And if your machines were taken offline in anticipation of the installation, delays extend unplanned downtime – potentially impacting delivery commitments and disrupting work among operators and supervisors. Each day of delay also leaves you susceptible to falling behind competitors who are busy optimizing their shop floor performance.

Scrap that vision of last-minute scrambling.

Instead, let’s see how you can maximize the installation process and avoid wasting billable service hours with these four practical steps. Your future self (and your CFO) will thank you.

  1. IT & Network Preparation. Start out by installing any required software onto a dedicated PC/server that meets the system’s requirements. Ensure administrative permissions are set for installation and test user logins and any necessary database connections. Apply all Windows updates/patches and have your PC on your network. Open necessary ports for firewall and network access and assign static IP addresses for all relevant CNC machines. Verify Internet and internal network access; if a proxy or VPN is needed, configure it in advance.

💡 Pro Tip: Running a quick pre-installation network check can prevent hours of billable troubleshooting.

  1. Facility & Equipment Access. Prior to your technical installation, secure machine access by powering on all CNCs and granting the technician permissions, like the ability to restart machines, as required. If an escort or safety orientation is mandatory, arrange or complete it before the technician arrives. Prepare the technician for your specific manufacturing environment by confirming any PPE requirements beyond steel-toe shoes and safety glasses. Ask your manufacturing integrator about standard service hours to ensure that overtime demands are minimized. Be sure to have essential personnel, including staff in IT, Engineering and Maintenance, on standby to assist immediately if needed.

💡 Pro Tip: Every minute a technician waits for access or approvals is wasted.

  1. Machine-Specific Configuration. Validate that data collection setup is ready and cabling and connectivity is set. Confirm network drops or Wi-Fi credentials are valid and tested. Keep this information on hand for the technician’s reference.

💡 Pro Tip: If a new installation is involved, lean on personnel familiar with the machine controller and operation to assist with machine parameter changes if needed.

  1. Final Check-In & Testing. Confirm all pre-installation steps with your manufacturing integrator. Double-check that hardware, adapters and licensing is ready to go. Lastly, validate the expected data collection method, machine connectivity to the server and openness of required ports and firewall rules.

💡 Pro Tip: A quick pre-installation test call with tech support can prevent major headaches and productivity losses on installation day.

Now picture this: The manufacturing integration technician arrives to implement your modern machine monitoring, PDM or DNC software. Before the technician’s arrival, your IT team has already confirmed network connectivity, ensuring IPs are valid and firewall settings are configured. You have software pre-installed, permissions granted and a pre-check conducted with your technician.

Busy manufacturer benefitting from its shop floor software and hardware implementation.

With the right manufacturing integrator and the right prep, your team can start realizing ROI from your shop floor software and hardware quickly, efficiently and effectively.

Once onsite, the technician gets straight to work, efficiently installing and configuring the software. Within minutes, your team is seamlessly accessing real-time data streaming from the machines, organizing CNC programs with revision control or transferring CNC files. Machine uptime is restored and personnel can continue about their day. Instead of frustration, the project ends with a successful implementation and a future-ready manufacturing floor.

Preparation is the Key to Success

A poorly prepared installation of shop floor software and hardware can easily cost thousands of dollars in billable hours, downtime, lost productivity and delayed ROI. Plan ahead with the manufacturing integrator experts at Shop Floor Automations to experience a smooth install, faster operational benefits and lower total costs – contact SFA today.

Equipment monitoring software for maintenance
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The Dilemma of Do-It-Yourself Equipment Monitoring Software

Downtime – and the response time to it – continues to plague manufacturers across the United States. A 2022 Siemens report revealed that a typical large plant “still loses 25 hours a month to unplanned downtime.” They estimate the cost of an hour of downtime to be $500,000 for oil and gas companies, which makes downtime quickly cost millions.

As a result, teams are responding by gathering internal technical requirements, evaluating off-the-shelf machine monitoring solutions and attempting trial implementations. Top machine monitoring solutions will capture data from new and aged CNC equipment and deliver trends and reports using configurable dashboards via modern communication tools, like text and Microsoft Teams, to help you pinpoint production bottlenecks and machine condition degradation for improved Overall Equipment Effectiveness (OEE), quality control and profitability.

CNC machine monitoring for downtime monitoring

But there are hundreds of available equipment monitoring software solutions today, ranging from Predator Software to Scytec DataXchange and beyond, and the equipment monitoring market itself is projected to reach 220.92 million USD by 2031. This makes the vendor decision-making process all the more onerous and lengthier, particularly for time and labor-constrained companies. Some manufacturers are instead taking on a Do-It-Yourself (DIY) approach by assembling internal and/or outsourced developers, collaborating with various departments and rolling out a custom solution. There’s an attraction to this path, but is it truly the right way toward achieving more uptime, better operator performance and greater profits?

If you’re considering or already headed in this direction, you very well may consider the positive and negative aspects of DIY equipment monitoring development to fully validate your decision. As a manufacturing integrator experienced in helping manufacturers search, select and implement the ideal machine monitoring software solution for your business, the experts at Shop Floor Automations have compiled a comprehensive list to aid your research below. We welcome your comments on other advantages and disadvantages that factor into your own machine monitoring evaluation.

The Pros of DIY Equipment Monitoring Software Development

  • Potentially less upfront cost. When your teams develop equipment monitoring software in-house, you’re not likely to incur the recurring software subscription or license fees demanded by software vendors. Software subscription revenues are anticipated to grow by a CAGR of 16.6% reports EY, as enterprise technology companies continue to shift away from a perpetual software license model. You also have the benefit of leveraging existing programmable logic controllers (PLCs) without upfront costs for hardware and training to program it.
  • Built your way. Machine monitoring software designed for your business can be customized to accommodate your specific business processes, equipment types, locations, unique terminology and standards, integrations and more. You’re not forced to adapt to the user interface, limitations and future development of a commercial application geared for a mass of users.
  • Vendor neutral. A DIY equipment monitoring project allows you to be in control, deciding who is involved and how the system and data is maintained, supported, secured and located. Conversely, a machine monitoring software provider will often dictate the supporting partners and underlying ecosystem available with the solution – which can require data hosted by their third-party provider.
  • Fringe benefits of familiarity. When you’re able to dedicate your resources to your own project, you can command your own timetable, training program and the coordination of subject matter experts. There’s less of an educational barrier, too, as teams should be familiar with the corporate nomenclature, key personnel and strategic priorities. The purchase of a commercial application like equipment monitoring software, however, means you are beholden to the skills, bandwidth, language and processes of the technology provider and the demands of their existing customer base.

The Cons of DIY Equipment Monitoring Software Development

  • Susceptibility to higher Total Cost of Ownership (TCO) and other impacts. The TCO of your DIY equipment monitoring system goes beyond just IT salaries; often the continued energy costs, hardware, security, training, networking, backup, testing and more will make this project far more expensive than commercial applications. Your custom software would also likely be impacted significantly by change: budgetary constraints, shifts in strategic objectives and corporate systems and policies, personnel movements and other factors. As a dedicated technology business to many users, the commercial developer tends to better absorb and rebound from events like employee attrition and economic impacts.
  • Competing departmental prioritiesLess emphasis on contingency and continuity. As an internal project, DIY machine monitoring software can be more prone to decreased attention over time, particularly if the project champion has left for another opportunity or moved to another department. The software and its related documentation and training programs, then, are less likely to stay current or remain relevant as new technology and security protocols are introduced to the business, new machinery is acquired and older machinery is retired or networks are upgraded. In this age of rapid change, software that sits doesn’t help a bit.
  • Forfeiting best practices. Custom software, such as DIY machine monitoring, inherently lacks the benefits that come from applying industry best practices, including data trends across wide swaths of users and equipment types, new AI developments, the latest security standards and other technological advancements that require research, resources and large, varied datasets. The core competency of software vendors often affords them greater focus, expertise, budgets, data access and more to help customers refine their business processes through proven functionality.
  • Shouldering the burden of ongoing maintenance and improvements. New requests for features require manual updates to hardware when working with DIY machine monitoring software. Maintenance technicians, for example, have to update the PLC hardware to capture each additional signal desired by internal management. This step may need to be replicated for each machine tool, which can be time-consuming and requires additional documentation to capture every change. Commercial machine monitoring, on the other hand, enables configuration via a web browser without the need to physically walk to the equipment.

In this age of rapid change, software that sits doesn’t help a bit.

Custom machine monitoring applications tend to be rigid in design, requiring a multitude of support tickets to increase flexibility as users engage with the software over months and years. Commercial equipment monitoring solution providers, alternatively, configure the System Resource Controller (SRC) and deploy changes easily. Their solutions tend to be out-of-the-box configurable for user control of reports, charts, and dashboards based on your machine brands. Software developers also have streamlined processes in place to accommodate continued development schedules and software enhancement and integration requests.

A DIY approach to equipment monitoring software can appear practical, especially for manufacturers with in-house IT development. But it’s important to look beyond upfront factors to include the entire scope of such a project, so that your TCO encompasses all opportunity costs, barriers necessary to overcome and anticipated internal and external changes that will impact short- and long-term development. After all, a deviation from core competency can be a costly mistake for manufacturers already reeling from downtime and production loss.

Ransomware on CNC Machines
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Building Resistance into Aged CNC Machines

How CNC program transfers can overcome the vulnerabilities of SMB1 for greater security and efficiency

It took mere hours. In May of 2017, a devastating ransomware cryptoworm called WannaCry impacted more than 200,000 computers across 150 countries, ultimately amassing over $4 billion in damages. Only months later, a variation of this worm spread to 10,000 machines in Apple’s single supplier of SoC components for iPads and iPhones, causing a production stoppage for a full day and shipment delays among its major tech customer base. The original worm was halted, but IT services management company Cloudflare asserts that WannaCry attacks continue today.

Ransomware on CNC Machines

The ransomware cryptoworm WannaCry notably affected TSMC, which manufactures processors and other silicon chips for major technology companies such as Qualcomm, AMD and Apple, due to a Windows SMB1 server vulnerability.

Starting with SMB1

What happened to the National Health Service (NHS), FedEx, Taiwan Semiconductor Manufacturing Company (TSMC) and so many others? The WannaCry worm exploited “vulnerabilities in the Windows SMB v1 server to remotely compromise systems, encrypt files and spread to other hosts,” explains a fact sheet from the National Cybersecurity and Communications Integration Center (NCCIC). While patches have since been issued by Microsoft, the software company admits there are still instances in which manufacturers may need to run SMB1:

    1. Your company is running XP or Windows Server 2003 under a custom support agreement
    2. You have old management software that demands admins browse via the “network,” also known as the “network neighborhood” master browser list
    3. You run old multi-function printers with antiquated firmware in order to “scan to share”

For manufacturers experiencing such cases, there are workarounds. SMB1 could be disabled on every system connected to the network, recommends the NCCIC. You can block port 445 (Samba). You can verify that there isn’t any unexpected SMB1 network traffic. You can isolate vulnerable embedded systems. But these options may not necessarily be viable for efficient and protected CNC file transfers among aged equipment.

Transfer CNC Programs on SMB1 Machines

Manufacturers can struggle to disable SMB1 on every machine and still transfer CNC programs efficiently, effectively and securely.

Simplifying Network Setups

An alternate route is to simplify network setups altogether. A modern DNC software, like Predator Secure DNC, enables you to remove Windows shares, corporate domains, workgroups, homegroups, Microsoft SMB, CFS, FTP, DNS, WINS, NETBUI and IPX/SPX within shop floor VLANs, WANs or subnets for DNC or file transfers. This can be especially useful for manufacturers running older CNC equipment with Windows-based controls that lack compatibility with newer operating systems. It can also alleviate the need for system upgrades and service packs to maintain the older versions of Windows.

The original WannaCry worm was halted, but Cloudflare asserts that WannaCry attacks continue today.

In other cases, controllers like Haas classic controllers can be upgraded to another SMB version by contacting the machine tool builder or segmenting the network to address CNC machines that are not upgradable or do not run a Windows operating system. The point is, regardless of your SMB1-dependent machinery environment, you can reduce your ransomware risk while gaining the latest benefits in efficiency and productivity.

An experienced manufacturing integrator possesses the technical expertise to properly assess, assign and execute custom solutions for your company. Contact Shop Floor Automations to understand your full scope of SMB1 options today.

Scrap material in manufacturing - Shop Floor Automations
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Revise Your Revisions: Scrapping the Rework from Poor CNC Production Documentation

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
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Map Your Show with this IMTS 2024 Exhibitor Lineup

“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
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Upgrade DNC Software & Streamline Your CMMC 2.0 Compliance

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 (DoD) on December 26, 2023. While these rules are published for comment, the codified version isn’t expected to change too drastically, however, DNC software upgrades may be something to consider, and Shop Floor Automations can help.

Townsend Bourne, partner at Sheppard Mullin, noted during an 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 who 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.

An ideal DNC software, which is a system that leverages Industrial Internet of Things (IIoT) and connects your shop floor equipment on one network, could be hugely beneficial. An upgraded DNC system can reduce or eliminate manual user authorizations, device logs and documentation for more streamlined CMMC 2.0 compliance and the prevention of USB CNC program transfer attacks.

 

Not only does this allow for CMMC 2.0 compliance, but DNC software upgrades also can streamline your entire operation. For instance, with Predator DNC software, you can network all CNCs, EDMs, PLCs and robots with a singular DNC package. At Shop Floor Automations (SFA), we have been the top Predator reseller for 20 years, and we also are a top provider of proven software from Scytec and Ascendant Technologies.

 

The team at SFA can provide you with DNC solutions for any brand, connection type or age of CNC machine. Additionally, we offer hardware solutions that can revolutionize your shop floor. To learn more about our machine monitoring solutions or how DNC software can aid your CMMC 2.0 compliance, contact an SFA representative today.

operator at cnc control
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Avoid the Rabbit Hole of Fixes for Antiquated DNC Software

Your aged CNC machines and legacy 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 are 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 DNC software setup. This can often be the impetus for Original Equipment Manufacturers (OEMs), contract manufacturers and job shops to re-evaluate 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 Predator 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 are a few recent DNC enhancements that have helped manufacturers realize these benefits by simplifying DNC 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.

 

Upgrade Your Predator DNC Software Today!

At Shop Floor Automations, we are proud to be the top distributor of Predator software in the United States. We strive to provide custom DNC software solutions that will streamline your operation and boost productivity. Contact us at any time to discuss your software, hardware and machine monitoring needs.

Manufacturing Forecasts 2024

Manufacturing in 2024: AI, Cybersecurity & DNC Software

At Shop Floor Automations, the top provider of DNC software in the United States, we find it crucial to stay on top of all of the latest manufacturing trends and predictions as these may affect your goals, plans and budgets for the year ahead. As 2023 winds down, it’s an ideal time to peer into the manufacturing crystal ball for 2024.

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. The use of a single DNC network comes 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” machine monitoring 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 and beyond.

 

At SFA, we are committed to providing our clients with the best DNC solutions. For 20 years, we’ve been the top reseller of Predator software, including Predator DNC, PDM and MDC software. Contact SFA today to discuss your strategic initiatives of tomorrow as well as discovering DNC software solutions that will give your business a competitive edge.

CNC Programmer Transferring Files

DNC Software & Solving For PCMCIA Card Failures in CNC

PCMCIA cards 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. DNC software can help, but first, let’s look at the two main ways this can cause disruptions.

 

  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.

 

  1. 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.

 

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 more than 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.”

 

DNC Upgrades: Prevent PCMCIA Card Failure

Upgrading your DNC (Direct Numerical Control) system can significantly reduce the risk of PCMCIA (Personal Computer Memory Card International Association) card failures through several key improvements:

 

  • Enhanced Compatibility: Upgrading your DNC machine software improves compatibility with modern hardware, including PCMCIA cards. This ensures seamless interfacing, reducing errors and failures caused by compatibility issues.

 

  • Bug Fixes and Stability: DNC system upgrades come with bug fixes and stability enhancements. These updates resolve issues that may cause PCMCIA card malfunctions, such as data corruption, communication errors, or unexpected disconnections.

 

  • Improved Power Management: Modern DNC server software includes advanced power management features. These features help prevent PCMCIA cards from overheating or experiencing power surges, maintaining their health and extending their lifespan.

 

  • Enhanced Data Integrity: Upgraded DNC software incorporates advanced error-checking and data integrity features. These features ensure that data transferred to and from PCMCIA cards is accurate and intact, minimizing the risk of data corruption and card failure.

 

  • Firmware Updates: Some DNC machine software upgrades include firmware updates for connected devices, including PCMCIA cards. These updates optimize performance and address known issues that could lead to card failures.

 

  • Better Diagnostic Tools: Newer versions of DNC software offer improved diagnostic tools to identify potential issues with PCMCIA cards before they fail. Early detection allows for timely intervention and preventive measures.

 

Security Enhancements: 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.

 

Upgrades often include security patches to protect your system from malware and other threats. Since PCMCIA cards are used for data storage and transfer, enhanced security helps prevent data loss and card damage due to malicious software.

 

Regularly updating your DNC system ensures optimal performance and reliability of all connected components, including PCMCIA cards, thereby reducing the risk of failures.

 

At Shop Floor Automations, we offer DNC solutions to ensure that your shop runs as smoothly as possible every day. To talk to a DNC software expert and start exploring a modern solution to your PCMCIA card failures, contact SFA today.

Ethernet CNC connectivity
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Overcoming the Risks of Outdated Windows-based CNC Machines

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.