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.

A desk with many piles of paper scattered over it, which can be fixed by going paperless with the use of computers and PDM software.

Many machinists, production managers, and other shop floor workers wish they had paperless manufacturing. It feels like an impossible pipe dream to them.

It may be trendy to do so, but we wish to quote organizational expert Marie Kondo. Her insight is wonderful when thinking of taking on the daunting task of going paperless.

“People cannot change their habits without first changing their way of thinking,” Marie says in her book The Life-Changing Magic of Tidying Up. “Clutter is caused by a failure to return things to where they belong. Therefore, storage should reduce the effort needed to put things away – not the effort needed to get them out.”

Other than the need to be organized, there are far more important reasons to go paperless. Digital revision control, being prepared for audits and keeping track of crucial documentation also weigh heavy on our daily processes.

Yes, the task of going paperless can take time. But it is not an impossible task. Shop Floor Automations has even successfully gone paperless!

There is also a terrific article written by Eli Plaskett of Modern Machine Shop on this topic. His December 2018 piece “Turning the Page on the Paper Workplace” details a few steps to achieve this goal.

First, analyze how to give your workforce digital access to files as appropriate.
Invest in a scanner – for existing paperwork and whatever paperwork comes in the hereafter, scan immediately. Train employees to get into the habit of scanning.

Then, install tablets, network computers or digital station work devices. The next step is to train the workers fully on how to use the system. Show them the ways the system works for their benefit to save time.

Set up simple instructions such as photographing a setup. If you use ERP Software (which integrates with quite a few of our solutions), it can often have tools to enable photos attached with set up instructions or photos via an ERP smartphone app.

SFA has many solutions to help you cut your dependency on paper. We have USB hardware that can store programs in flash drives, and we highly recommend investing in PDM.

Ready to start the conversation? Call (877) 611-5825 or fill out our contact form

A shot of the side of a metal cutting machine, showing the leftover metal chippings and debris.What is lean production? One can view it as an alternative term for lean manufacturing, but we wanted to take a deeper look.

“Lean production is centered on determining what activities or processes add value by reducing other aspects,” this Techopedia article explains.

So there is our concept: instead of focusing purely on the bad (what processes to get rid of), we choose to focus on what is working. What can we magnify in order to increase production?

The first part of the equation is always your talent on the shop floor. Without people at the equipment doing the work, nothing happens. So how can we help?

“In lean-production systems, a manufacturer’s employees are organized in teams,” this Economist article explains. The article goes on to explain how the team structure works.

“These tasks are less narrowly specialized than those demanded of the worker in a mass-production system,” they describe. “This variety enables the worker to escape from the soul-destroying repetition of the pure assembly line.”

What kind of teams can you form on the shop floor to help with productivity? We suggest taking on these projects with Shop Floor Automations’ help towards the overall goal of lean production:

  1. Lights Out Manufacturing – This will require a specialized team to evaluate where there are snags in the process in order to do 24/7 machining. Especially if you have team members who work different shifts, this helps them to compare data and see what is happening.
  2. CNC Revision Management – Assign a team to investigate if programs are floating around the shop floor that needs to be better controlled. This team will help make sure old revisions aren’t running at machines.
  3. Going Paperless – Have a team designated to help the shop floor go paperless. Take on a system of real-time dashboards versus spreadsheets or whiteboards. This team can even help the front office out for a real sense of teamwork.

For solutions that will help with these team goals, contact SFA. Call (877) 611-5825 or fill out a contact form today.

CNC Revision Control is overlooked on the shop floor. Raw material and time are wasted when old programs run at machines.

CNC Revision Control“Revision control is the management of modifications done to software applications, sites, documents or any set of information,”

This definition is from Techopedia. Benefits of this concept include better record keeping, performance analysis, collaboration, and more.

Modern Machine Shop columnist Wayne Chaneski says evaluating shop floor programs is crucial for success.

“It is hard to know if a process needs to be fixed if it is not being followed as intended…valid processes that have veered off course may require additional employee training or better communication of expectations.”

So what is a huge issue to resolve, according to Chaneski? “Instances of different computer numerical control (CNC) programs for the same part with the same revision code.”

cnc drip feedBefore retiring from Buck Knives, Shop Floor Automations customer Lee said this was a daily battle. Because of issues with programs, it was a productivity roadblock.

“We had programs pretty much stored everywhere,” he said. “What we needed to do was lock down the programs,” Lee stated. Buck Knives resolved their issues, and they weren’t alone.

“We were trying to control over 8000 programs, revision levels, and updates,” says Wayne of Carrol Machine.

Revision control helps the shop minimize the time and mistakes of manual program management. Revision control also allows for grabbing programs from the right directories.

Ready to start the conversation about your manufacturing equipment? Call (877) 611-5825 or fill out a contact form today

The following is an archived copy of our May 2018 newsletter sent May 22nd. Subscribed, but not receiving newsletters? Get more info on this page!

Shop Floor Automations NewsletterDoes getting your shop floor paperless, organized, ready for an audit, and functioning sound impossible? Trust us. It’s not.

The Predator Software Suite contains a solution called PDM, or Production Data Management. You can use PDM to organize programs, safety procedures (such as lockout/tagout and other OSHA standards), setup sheets, quality documents, and more. Use PDM to help obtain revision control, as well as to finally go paperless.

Every department can find a benefit from PDM. Whether they work in engineering, programming, or quality – everyone on the shop floor has a reason for document control. Especially when auditors will be checking if you have management and sign-offs for your processes and files, this solution is especially crucial.

PDM will integrate with other pieces of the Predator Software Suite, such as DNC (CNC networking software), CNC Editor, MDC (Machine Data Collection), and Tool Tracker. It will also integrate with ERP and MES software systems.

Seeking out CAD/CAM software for your growing manufacturing operation? Especially one that can integrate with our solutions?

BOBCAD is a CAD/CAM company we have been working with for quite a few years. Especially since it integrates with some of our most popular solutions, such as DNC software, machine monitoring software, and our USB Connect hardware. Yes, it will even integrate with the PDM software mentioned above!

Shop Floor Automations is the number one reseller/integrator of Predator Software. Call (877) 611-5825 for a quote and more information. Link to original newsletter

cnc control

Click the photo to see the full detail of these hilarious CNC control operator buttons!

Everyone works differently on the shop floor. Some machinists use sticky notes, or custom stickers on machines, other use full sheets of paper to leave notes, and there are others who embed reminders in their coding. That being said, here are some funny CNC control photos we have seen over the years!

SFA has serviced all manner of manufacturers over the years. We have helped increase productivity for CNC machinists, fabricators, moldmakers – you name it! We are also fascinated with the #instamachinist movement on Instagram. Read more below!

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A monkey wrench style ruler grips several US coins on top of ROI paperwork.As a manufacturer, you have a lot of daily concerns, such as downtime and productivity. Is your manufacturing ROI an issue that is falling to the wayside?

With a new year coming up fast, your ROI (or return on investment) should be bumped up to one of your largest concerns, if it is not already. You may remember when we did a previous blog explaining different types of costs for a manufacturer. For this blog post, we wanted to take the time to explain the top 3 ways that working with a manufacturing integrator like Shop Floor Automations will help you with ROI!

#1 Reduce procurement costs:

The only time you ever want the amount of money you are spending on raw materials to go up is because your productivity is at sky-high levels. Unfortunately, you may be spending a lot on raw materials due to downtime on the machine interfering with the quality of products. You may even be spending a lot on paper for spreadsheets and other shop floor documents. Using tools such as machine monitoring software can help you increase utilization of machines, and combining products like job scheduling software and PDM software can help you go paperless. Do you still use floppy disks or constantly invest in CAT-5 cable that needs to be replaced and restrung once a year? Invest in new hardware that will replace these processes and old media sources. These solutions should help bring down some significant procurement costs.

#2 Time-sensitive efficiencies:

Manufacturing is one of the most time-sensitive processes in the world. Certain quantities need to be done perfectly and they need to be on time. What happens when downtime takes down one of your machines? Or you have to spend time manually updating spreadsheets for your production schedule? Or your CNC’s have communication failures on a regular basis? Using the tools of DNC software for CNC communications, machine monitoring for combatting downtime, and graphical job scheduling to be able to see production changes in real time, all make for the perfect trinity to help jobs get out to customers on time.

#3 Marketplace advantage:

American manufacturing is coming back to a place of significant prominence. While the industry deals with a skills gap combined with reshoring, you need to make sure you can take on as many jobs as possible to stay ahead of the competition. If you spent less time updating spreadsheets, invested in less overtime to fix human error and were able to prevent more downtime on your shop floor, imagine how many more jobs you can take on. Implementing any of the tools mentioned above can help with productivity and cement your place in this industry as a top manufacturer.

If you are interested in these solutions, please fill out a contact form or call us at (877) 611-5825 

Predator SoftwareSummer 2017 Predator Software Updates

Shop Floor Automations is excited to share with you these Summer 2017 Predator Software Updates:

  • In August, July & June, there have been the following updates to MDC:
    • v11.0.248 (August 10, 2017) Improvements for Favorite Reports. Improved New Events Touch manual collection of user logins, machine downtime, good parts, scrap parts, and more. Machine Events Reports improved. Bugs fixed for Machine Downtime and Cost chart legends, and overall load on the database instance has been reduced. Many more improvements made.
    • v11.0.246 (July 14, 2017). Improved MDC APIs and bug fixed with running reports from View Components.
    • v11.0.245 (July 7, 2017). Duration of Chart has been added to header.  Automatic and manual refresh logic improved. Multiple display elements improved. Overall chart performance, use of arrow keys, part serial number permissions, and similar features improved. More updates, as well as some bug fixes, included in this version.
    • v11.0.241 (June 8, 2017). Chinese, Japanese, and Korean style reports added. Improvements made to MDC Service Manager, View Machine Status, View OEE Status, Chinese language resources, Production Trend Analysis Chart display, and more features. Bugs fixed and more improvements made.
    • Android compatibility was also improved for MDC in late June 2017.
  • On July 16, 2017 – Predator Tracker v11.0.55 was released. Same as PDM – FIPS compatibility with FLM v11.0.0.2. improved. New imports and API abilities added. Improved process for Check-in/Check-out to Departments, Locations and Groups. Bugs fixed with View Components reports, editing tool rework operation definitions, and more.
  • On July 15, 2017 – Predator PDM v11.0.174 was released. FIPS compatibility with FLM v11.0.0.2. improved. Part serial number permissions, importing manufacturing/quality requirements, online help, and PDM APIs have been improved. Bugs fixed with assigning icons to custom commands, and more.

There have also been updates for Predator CNC Service, Predator Travelers, and Predator FLM over the summer.

If you would like more information, please contact SFA by calling (877) 611-5825 or fill out a contact form at this link

People try out new technologies each day. The manufacturing industry is no exception.

They buy new phones, lease new cars, upgrade the software on their phones and computers, or add implements to their homes to improve their quality of life. Embracing new technology is a move that would benefit the manufacturing shop floor industry most.

A woman stands at the airport looking at 3 machine monitoring screens related to the status of her machine at the shop. A blue text bubble coming from her backpack says "Text: Downtime. Machine 2. Department notified."Here are the Top 3 ways that new manufacturing technology adopted on the shop floor can benefit your company:

1 – You can keep up with the competition. According to recent results from the Manufacturers’ Outlook Survey, the National Association of Manufacturers states that in 2017, there is a record-high level of optimism in the manufacturing industry. 91.4 percent of manufacturers said they would increase investments, hire more workers, and that they generally feel good about our industry’s growth. Do you fit in this category?

Are pieces of old tech, like floppy disk drives and handheld terminals holding you back? Are you experiencing communication failures due to lack of CNC memory for your programs? These are all problems that new technology can fix, so that you can get in on this wave of prosperity.

2 – Increase profit. When implementing new hardware and software into older machines, this can help drastically decrease downtime. When there is no downtime to deal with, or less of it, machinists are free to perfect their craft. According to SME, there have been proven studies that show on average, time will decrease 5 percent every time the number of completed pieces doubles.

Therefore, if a machinist has more time to actually do their job than deal with machines going down, that will ultimately make the company more productive. Implementing machine monitoring to track machine trends increases OEE and DNC software can help with CNC communication failure, which are two sure fire ways to combat downtime.

3 – More freedom. When there is less worry of machines going down, this can create a better work/life balance for those who work on the shop floor, and in the front office. Machine monitoring, which is a powerful IIoT (industrial internet of things) tool, is an amazing way to get notifications of what is going on with machines not only on the shop floor, but via email or text notifications.

When this proven solution to deal with downtime is combined with more accountability through the means of graphical job scheduling, PDM, and other resources on the shop floor, there is more trust in the workplace. More people can use their PTO to go on vacation, or workers who are home sick can help give guidance when a machine goes down via a notes section through machine monitoring.

If you are interested in new technology for your shop floor and experiencing the benefits listed above, contact us by filling out a sales form here, or call (877) 611-5825.

 

pdmPredator PDM Enterprise has enhanced the shop floor dialogs with New Machine Events and Tracker style Check-In and Check-Out dialogs. In addition, the following improvements have been made:

January 17th 2013 – Predator PDM v10.0.191 is released

  • Added -UNRELEASED to change manufacturing and quality status workflow
  • Improved online help
  • Improved -viewvaultitem command line to support wildcards
  • Improved -viewvaultitemdialog command line to support wildcards
  • Improved machine wizards
  • Improved the Oracle database login screen
  • Improved displaying the database name and host within the status bar
  • Improved check-out warning message
  • Improved display of LF only style CNC files within the shop floor windows
  • Fixed a bug with editing a list item
Customers on software maintenance can download v10.0.191 of Predator PDM from our downloads at any time. Customers running v9 or older of Predator PDM should contact Shop Floor Automations for upgrade details and pricing. Read more below.

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