Everything Revolves around Tools - TDM Systems€¦ · 10 Everything Revolves around Tools ... That is why we talk about Tool Lifecycle Management today. ... It is nothing more than

Everything Revolves around Tools

05-2015

Magazine for Customers, Interested Parties and Employees of TDM Systems

4STRATEGY

TDM unites Businessmen, Designers, and Manufacturers

8SOFTWARE

TDM Global Linemarks the Start of a new Generation

14PRACTICE

The Networking of Three Worlds: Interview with Prof. Jivka Ovtcharova, Karlsruhe Institute for Technology (KIT)

2 TDMessage 05-2015 TDMessage 05-2015 3TDM Systems · www.tdmsystems.com TDM Systems · www.tdmsystems.com

STRATEGY

4 TDM unites Businessmen, Designers, and Production Workers . . . . . . . . . . . . . .

The World of Tools opens itself to "Industry 4.0“

NEWS

6 News about TDM Systems and TDM Software . . . . . . . . . . . . . . . . . .

SOFTWARE

8 TDM Global Line marks the Start of a new Generation . . . . . . . . .

Interview with Adir Zonta Jr., TDM Systems

20 Overview of the Crib Reduces Machine Downtimes.

The TDM Tool Crib Module

PRACTICE

10 Everything Revolves around Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TDM User Norbert Kempf GmbH, Germany

16 Information and Exchange

Participant Comments from TDM User Day 2014

TDM INSIDE

13 Webinars for Important Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interview with Waldemar Geweiler, TDM Systems

22 Globalization of the TDM Systems

Service & Support Centers

Presentation of a New Concept

PARTNER

14 The Networking of Three Worlds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interview with Prof. Jivka Ovtcharova, Karlsruhe Institute for Technology (KIT)

18 "Helping Provide Appropriate Priority To Tool Management"

Interview with René Taillade, TDM Sales Partner for France

It sounds logical that hardware and software

should be integrated, and if possible, systems and

infrastructure, as well. Nevertheless, digitally net-

working them digitally is a is a huge undertaking.

If, on top of that, it needs to facilitate intelligence

in the workplace, even more so. Because over the

years, a veritable zoo of data and systems has

grown in many companies, which can only be

linked with difficulty. However, we all know: There

is no alternative.

The roots of TDM Systems reach back to the first

major networking wave, which in the '80s was

known as "CIM" (Computer Integrated Manufac-

turing). To date, we have continously worked on

digitally mapping everything that belongs in the

narrow and broad sense to the digital manage-

ment of cutting tools. Thus, we have created the

basis that in a manufacturing world, with its ev-

er-increasing complexity, all of the important in-

formation flows together - and everything, on any

device, mobile or at the machine, is available and

in the future also ready in the "cloud". That is why

we talk about Tool Lifecycle Management today.

Networking is by far not only a technological

task. On the contrary: Technology always needs

humans. Companies that want to be successful

today need team spirit and cooperations. This is

particularly true for companies that are innova-

tive. TDM Systems is therefore now cooperating

with the Eastern Bavarian Institute of Technology

(OTH) Regensburg and the Karlsruhe Institute for

Technology (KIT). Together with other IT compa-

nies, including the computer retailer Bechtle, and

SolidLine AG, we are working at KIT in the "Indus-

try 4.0 Collaboration Lab" on concrete applica-

tions such as ways that medium-sized companies

can benefit from the Smart Factory. An intelligent

networking of manufacturers and research for the

advantage of SMEs. Read more in the interview

with Prof. Ovtcharowa from KIT, on Page 14.

With TDM Global Line, we show you how network-

ing tool data management leads to more, interna-

tionally available intelligence. With it, you can use

all of the advantages of our data base in your sub-

sidiary companies - and in fact, completely device

independent. This global solution is a big step to-

wards international production standards, Indus-

try 4.0, integration - and especially cross-border

and cross-domain collaboration. Which brings us

back to our starting point: Networking facilitates

intelligence.

If you rely on the right tools.

Sincerely Yours,

Peter Schneck

Managing Director TDM Systems

Intelligent and Networked

EDITORIAL

TDMessage

TDMessage is the Magazine

for Customers, Partners,

Interested Parties and Em-

ployees of TDM Systems. It

is published twice a year and

can be subscribed through

TDM Systems GmbH.

Responsible for Content

Peter Schneck,

TDM Systems GmbH

Editorial Team

Daniela Steinhart,

Sandra Schneck,

TDM Systems GmbH

Anne Tritschler,

Storymaker GmbH

Layout/Graphic Design

Sabine Bräuning,

TDM Systems GmbH

Contact

Headquarters

TDM Systems GmbH

Derendinger Straße 53

72072 Tübingen, Germany

Ph. +49.7071.9492-0

Fax +49.7071.9492-707

[email protected]

www.tdmsystems.com

Office North America

TDM Systems, Inc.

1665 Penny Lane

Schaumburg, IL 60173, USA

Ph. +1.847.605-1269

Fax +1.847.605-0586

[email protected]

www.tdmsystems.com

CONTENT

CustomerOrder


The world of tools opens itself to "Industry 4.0". During the

latest TDM User Day in Ekrath, TDM Systems Senior Con-

sultant Thomas Mücke demonstrated how productive Tool

Data Management can help reduce product cost between

planning and production.

he processes of the manufacturing industry can be

further optimized only through an overall approach.

"That is the focus of the Industry 4.0 Idea, actually a logical

development of the system landscape in recent years," said

Mücke. It is nothing more than the automation and networking

of production systems from mechanical and electrical com-

ponents. Such systems provide information in the form of a lot

of data."The challenge is to prepare and use it, so that it brings

economic advantages."

According to Mücke, the "Tool Data Management" plays a

central role in Industry 4.0 connecting technical and business

departments. In many companies today, there are two funda-

mental structures side by side: A technical process, realized

through PDM (Product Data Management) or PLM (Product

Lifecycle Management) systems, and a business manage-

ment process, controlled by ERP (Enterprise Resource Plan-

ning) systems.

TDM as the Link

The Tool Data Management is networked with PLM/CAM

systems or BDE/MDE/MES systems, but also to the material

master and orders from the ERP system. Real-time informa-

tion from the machine helps to optimize the processes of both

areas even more and to reduce product and manufacturing

costs.

It has long been known that about 70 percent of the product

costs are already defined in the design. An example: Changing

the diameter of a hole from 10 to 10.2 millimeters requires only

a mouse click. However, if, the tool for the new diameter is

missing in the workshop, this causes problems that interfere

with the process.

By accessing appropriate tool data, the designer can already

see in his CAD system whether the production of the desired

TDM unites Businessmen, Designers, and Manufacturers

hole is possible in terms of efficiency. Prerequisites are tool

data with tool geometry and technical information about cut-

ting data, production processes, as well as machine informa-

tion. Thomas Mücke: "With this information, the designer can

perform a preliminary calculation to evaluate the feasibility

and the cost of the machining operations."

Data Flow is a Prerequisite for Industry 4.0

A seamless flow of data from the machine is a prerequisite for

process optimization and savings. The large amount of data

in the form of cutting data and feeds & speeds needs to be

organized, controlled, and stored. Machine connectors that

connect to the machine control system help this the return

of, for example, the remaining tool life, machine utilization, or

feeds & speeds of tools. "TDM can collect and store this data

easily; it provides comprehensive benefits in various areas,"

explains Mücke, who goes on to give an example: The remain-

ing tool life can be utilized for transparent crib planning.Tools

are inventory-optimized and promptly ordered, which reduces

storage costs and capital commitment. Real-time informa-

tion on machine utilization and condition of the tools allows

a flexible and prudent scheduling of production orders on the

machine. The con-

dition, use location,

or crib location of

the tools are taken

into account. Orders can be rescheduled with short notice

and produced with alternative tools, setup cost and times

are reduced significantly, "the machines and the tools can do

what they should: Produce!"

Putting the Focus on the Entire Customer Order

"The decisive factor is the customer order," says the TDM

expert: "The faster it is ready to ship, the faster it is billed." The

lead-time of a customer order should therefore be as short as

possible. Bottleneck machines with material jams can cancel

out any other achievements. Countermeasures can be taken

through alternative operations in the work plan or in the pro-

duction order.

The necessary NC programs require automated CAM pro-

gramming. Automatic feature recognition in the CAM pro-

cess with subsequent virtual simulation with data from TDM

ensure the pace and consistent quality. The optimal sched-

uling of production orders on the appropriate machines and

tools requires networked thinking. "For this purpose, APS

(Advanced Planning Scheduling) and MES (Manufacturing

Execution System) systems must be integrated."

Fast Information out of the System

A few typical examples show how this works in practice.

During maintenance,

the machine sends

information to TDM,

which is processed so

that the downtime of the machine can be planned for and min-

imized. If an operation is moved to another machine, TDM can

immediately release tools again for other jobs and thus reduce

the capital lockup. With real cutting data from the machine,

CAM systems can reduce the machining times and help the

construction. Such information will be available in the future

on all devices in real time. Since the data is always assigned

to the production order, it can be tracked. Thomas Mücke's

conclusion: "Networking promises significant increases in pro-

duction because the machines will ultimately produce more."

STRATEGY

T

The decisive factor is the customer order, the faster it is ready to ship, the faster it is billed.

If TDM is integrated into the planning and production systems, customer orders can be easily scheduled or rescheduled and prompt realization of orders in revenue can be ensured.

CustomerOrder


TDM Systems at the Expert Forum “Unmanned Production”

Thomas Mücke, Senior Business Solution Consultant at

TDM Systems will be giving a presentation about "Industry

4.0 in Practice - Integrated Processes with Tool Lifecycle

Management and NC Simulation for Optimum Machine

Utilization" at the expert forum "Unmanned Production".

The forum is organized by the trade press organizations

mav and Automation Practice and will take place on June

16, 2015 at Liebherr Verzahntechnik GmbH in Kempten. It

focuses initially, on suppliers in metalworking, component

manufacturers, and companies in mechanical and auto-

motive engineering as well as in

aviation; then secondly,

on heads of corpo-

rate internal milling

departments and

managers who

want to opti-

mize processes.

TDM Systems Introduces Students to Industry 4.0

In a pilot project, software from TDM Systems

is being used in the production technology

and machine tools lab of the Eastern Bavarian

Technical University (OTH; Ostbayerischen

Technischen Hochschule) Regensburg. "By

working with our software, the young engineers

learn a lot about the digital requirements of

manufacturing companies," explains Regional

Account Manager Andreas Maier. As a pioneer

in tool data management, TDM Systems is

planning further collaborations with engineering

programs and research institutions in order to

enable a transfer of knowledge and to establish

the link to practical application.

NEWS

TDM Systems Receives ISO 9001 Certification

TDM Systems is the first German IT company

to attend the TQMi seminar and successfully

complete the ISO 9001 certification. Here, a

special process-based management system

was developed and introduced during the last

12 months. The ISO certificate now confirms

the introduction and implementation of the

management system for the areas of devel-

opment and delivery of software solutions for

Tool Lifecycle Management, including needs

analysis, consultancy and sales; Installation,

training and services; Project management as

well as services for tool data creation.

Follow us!

Since the beginning of March, TDM Systems

has its own Twitter account. Followers can get

regular news from the industry and messages,

information, and articles about the company.

TDM Systems is also present on other social

media channels: Since April 2014, the company

has been posting videos on its own YouTube

channel. TDM Systems also presents itself as an

employer on LinkedIn. Last but not least, TDM is

a sponsor of the online portal IndustryArena, the

world's largest information portal for manufac-

turing technology. In our newsroom and in the

forum "Tool Management Systems," we put out

regular entries about the topic Tool Data Man-

agement to the professional audience.

Being part of the "PLM Industry 4.0 Collaboration Lab“

TDM Systems is working in a consortium together with

the Karlsruhe Institute for Technology (KIT) and alsev-

eral software suppliers to help build an overall pro-

cess chain and to optimize the processes even more.

The project "PLM Industry 4.0 Collaboration Lab"

is managed in the "Lifecycle Engineering Solutions

Center" (LESC) by Professor Dr. Dr.-Ing. Dr. h. c. Jivka

Ovtcharova, Head of the KIT Institute for Information

Management in Engineering (IMI).

To date, the following companies are involved in the

research project:

• TDM Systems, with TDM

• Geometric, with the CAM system CAMWorks

• Forcam, with the MES system Factory Framework

• Bechtle AG and its system house Solidline, with

the CAD system, Solidworks and Enterprise PDM

• Simus Systems, with Classmate Plan

Cost Reduction 4.0

How can product and manufacturing costs be reduced

with integrated solutions? That was the central topic

of a presentation given by Thomas Mücke at the Han-

nover Trade Show in April 2015.

As part of the event series "Industry Forum 4.0," the

Senior Business Solution Consultant at TDM Systems

explained the advantages of networked production

systematics. Mücke did not just explain the possi-

bility of a manufacturing suitable design, but also

on flexibility during production through to an overall

improvement process by a reflow of information.

TDM Systems is a Microsoft Silver Partner

Since February 2015, TDM Systems is an official mem-

ber of the Microsoft Partner Network and has suc-

cessfully completed the tests for Silver status. TDM

customers benefit directly from Microsoft's develop-

ment expertise, which is continuously incorporated

into the quality and innovation of the TDM software.

TDM Systems benefits, for example, through Mic-

rosoft licenses for customer demos and tests. Gold

status certification is expected later this year.

http://www.tdmsystems.com/sm/?wmc=SM_Banderole


SOFTWARE

TDM Global Line marks the Start of a new Generation

Mr. Zonta, what does

TDM Global Line mean?

TDM Global Line will extremely speed

up the tool data exchange of interna-

tional industrial companies with global-

ly distributed production facilities. This

is only possible because it is a new gen-

eration in software technology as well

as in application technology. Selected

customers will put the system through

its paces by the end of July. After that, it

will be available for all customers.

What is new?

We have focused on the software ergo-

nomics and the user experience. In oth-

er words, better handling, intuitive - the

The last tests are running and in August TDM Global Line will be launched.

An important step towards the future and Industry 4.0. TDMessage spoke with

Product Manager Adir Zonta.

functions exist where the user needs

them. The era of rigid screens is over;

now users can decide for themselves

how they display their information. The

user experience describes all of the us-

er's perceptions and responses that re-

sult from using a piece of software. With

its modern, reduced and intuitive soft-

ware design, we want to ensure that the

users feel comfortable with TDM Global

Line and that the software is accepted

quickly and positively.

Who should be interested in

TDM Global Line?

Basically, any customer. The first mod-

ule of the Global Line product line is

mainly for customers with several pro-

duction facilities. In TDM V4, Server and

Client share the computational effort.

Therefore, large amounts of data are

pushed back and forth between servers

and clients, which can especially lead

to performance losses over long dis-

tances and poor internet connections.

TDM Global Line has a new structure

and works primarily on the server, where

the central data base is located. The

streamlined client essentially only gives

commands and receives results, result-

ing in outstanding performance. The

highly compressed, demand-oriented

data transfer also supports the perfor-

mance.

How did you realize it technically?

TDM Global Line is based on a 3-tier ar-

chitecture system and follows the world

standards for desktops. It has been

programmed with .NET, whereby the

knowledge received through our Micro-

soft Silver Partnership was very helpful.

In addition, we will be able to offer a

browser solution with this technology.

And the best part: Despite all of these

innovations, TDM Global Line is fully

compatible with the existing TDM data

base, so that customers can expand

without any problems.

Which functions can customers

expect from the first version?

TDM Global Line is set up, similar to TDM

V4, in a catalog area (initially Sandvik

Coromant and Walter catalogs), an

item area, a tool assembly area, and a

tool list area. Users can therefore create

items from the catalog and assemble

tool assemblies. In addition, 1.0 already

has an easy booking function of the tool

crib management system and of course

includes basic functions such as a Goo-

gle-like search engine. The ability to

centrally manage client and user rights

is very important for many customers.

Another important aspect is the sig-

nificantly improved know-how transfer

from the head office to the production

facilities, which reduces costs in the

long run.

And where do we go from here?

With TDM Global Line, we have aimed

both the software as well as the de-

velopment towards the future. We op-

erate agile software development that

is transparent and pursues clear goals.

Furthermore, we use methods, which

Microsoft also is working with. Devel-

opment steps and functions are always

traceable, enabling sustainability and

transparency. Therefore, TDM Global

Line marks the start of a new genera-

tion and is an important step forward

towards the future.

TDM Global Line is already avail-

able now with its basic functions

as a demo. Make an appoint-

ment with your local sales

representative and ask to see

the handling and functions of

TDM Global Line.

Adir Zonta Jr.

Headquarters "N. America"

Location "Europe"

Location "Asia"

Centrally genera-ted tool and ma-nufacturing data ensure globally standardized tool use.

Optimum tool selection: Easy search function allows each employee to find the right tool.

Fast data access: Possible thanks to "1:1 Performance" from any location worldwide is possible.

Example for the Use of TDM Global Line


oolant seems to run in his veins: Stefan Kempf puts his

heart and soul into being the head of contract man-

ufacture at Norbert Kempf GmbH in St. Ingbert, a town in

Saarland, Germany. The company employs approximately

100 employees and manufactures parts and assemblies

for customers in the fields of pneumatics, hydraulics, au-

tomotive, construction machinery, and prototyping in 2500

square meters of space. Kempf also manufactures machine

pallets. Every day, about 2500 parts leave the operation.

At first glance, it is nothing special. However, a second look

is worth it. It is finally clear when Kempf shows the utiliza-

tion of his machinery through a projector in real-time: Things

work differently here. Almost all of the machines are in pro-

duction around the clock; the utilization rate is nearly 100

percent. Nevertheless, there is no hustle and bustle in the

halls; all of the work is concentrated, but relaxed, in short:

The shop runs. Many large mass production manufacturers

would be happy to push forward into these regions, even just

a little bit.

Reliable Processes are essential

Stefan Kempf has been working for Kempf GmbH since

1991, which was founded in 1970 by his father, Norbert, in his

own home "between the washing machine and the clothes-

line." He has been the sole managing partner for the last five

years and makes no secret of his recipe for success: "Our uti-

lization rates are based on absolutely reliable and reproduc-

ible process that can only be achieved through rational tool

management beforehand - TDM helps us with this."

For years, he and his employees analyzed the restricted crib

again and again in search of the causes of errors. Result: "60

to 70 percent of all errors are caused by mismanagement

of tools, assembly errors, poor radial or axial run out, wrong

individual items, or because the tool was not getting to the

machine on time."

Other factors played only a subordinate role. "I can some-

times bring machine pallets and workpieces quickly down

the hall to the machine with the forklift, but without tools,

my shopfloor comes to a standstill." Since coming to this

realization, the three main prerequisites for smooth produc-

tion are in his mind: The tool, the tool, the tool.

For every order that comes in, a process planning order is

The three most important factors of a property are: Location, location, location. And in manufacturing? Stefan Kempf, Head of contract manufacture, Nor-bert Kempf GmbH, knows the answer: "The tool, the tool, the tool." TDM enables the necessary con-trol over the tools.

Everything Revolves around Tools

triggered, from the production control plan via the Failure

Mode Effects Analysis (FMEA) to the design and CNC pro-

graming. "Our constant main topic," says Kempf, "is the set-

up costs-neutral production, which we handle using TDM."

The machines are standing still only for the initial setup of a

new part. All other setup processes take place outside of the

machines, while the machines do what they were built to do:

Machine around the clock.

Production with a System

In 2003, Kempf invested in a flexible manufacturing system

from the automation specialists, Fastems - a machining cen-

ter with twelve machine pallets. In 2011, the maximum expan-

sion level had been reached but still without upstream tool

management. "Then we started the largest project in the

company's history, the 'Project Kempf 2013'" - a new produc-

tion hall, the production system from Fastems MSL / CTS,

and the introduction of tool data management, TDM, which

supplies both flexible manufacturing systems with tools.

The core of the system is a high-rack storage, which houses

the machine pallets with the clamping devices and the raw

materials. A racking storage and retrieval vehicle transports

the pallets to the seven machining centers or to four loading

stations for mounting. The central tool storage unit that is

arranged at a right angle to this has space for 2500 tools

and a crib robot. The steel colleague sorts and puts away

new tools and brings worn tools to the withdrawal station. If

tools are needed on the machines, it passes them to a gan-

try robot that travels on rails over to the machine and loads

it into its magazine. This still only serves as a buffer.

This complex tool circulation is organized by TDM, which is

familiar with all of the important tool data, including their

remaining tool life, and knows exactly when and where each

tool is used. "We automatically provide each tool with an

RFID chip that contains all of the relevant data," explains

Kempf. Once the tool arrives at the machining center, geom-

etry data and tool life is read. "But above all, the remaining

tool life is communicated with used tools." And the system

thinks for itself. If a tool receives a tool life warning, the robot

delivers a replacement tool into the magazine chain on time.

[2]

[1]

Our utilization rates are based on absolutely reliable and reproducible process that can only be achieved through rational tool management beforehand - TDM helps us with this.

[3]

[4]

[1] Stefan Kempf, managing di-rector of Norbert Kempf GmbH.

[2] [3] Thanks to pre-defined and parameters provided by TDM, employees in the tool assembly can check the tools for plausibility at the same time and thus rule out errors in the assembly.

[4] The tool machines are in-terlinked on their rear sides by a pallet and raw material crib and on the top by a gantry robot.

C

Lord of up to 2500 Tools: The crib robot in the central tool storage unit from Fastems knows the exact crib location of every individual tool and passes it along to its colleague, a gantry robot, in a timely manner before it is used.

PRACTICE

TDMessage 05-2015 13TDM Systems · www.tdmsystems.com12 TDMessage 05-2015 TDM Systems · www.tdmsystems.com

Webinars for important Topics

Mr. Geweiler, what topics do you dis-

cuss in your webinars?

It is always about the TDM-software

and its modules. Customer requests are

also considered. Usually, there are three

parts that build on each other themat-

ically. Typical examples are the intro-

duction to the TDM Base Module, the

assembly of a tool assembly, and the

TDM Form Generator.

The webinars have been around for

about two years, who participates?

Only current customers with an existing

softwrae service and update contract.

Initially, we had up to 90 participants,

but that was of course the novelty ef-

fect. For many it was the first webinar

that they participated in at all. In the

meantime, it has leveled out at 30 to

60 participants.

Since 2013, TDM has offered monthly webinars alternating in German and in English about the TDM-software. They are

moderated by Waldemar Geweiler, longtime service technician who knows many of the participants personally. He reports

about news, refreshes knowledge, and provides tips. The webinars are part of the TDM-software service and update con-

tract, which also provides access to new software releases, the FAQ data base, and the "Service Desk."

How is the response?

Very good, we receive a lot of approv-

al. Especially praised is the fact that

new knowledge can be aquired quickly

without great effort for training. But one

thing is clear: A one and a half hour we-

binar cannot replace multi-day training.

How does a typical webinar go?

A link enables participants to go direct-

ly into the "webinar room," where they

first will see the talking points. Every-

thing else is live; the participants see my

screen with the TDM-software and hear

my explanations with their headsets.

Usually, we have about 20 minutes of

presentation and five to ten minutes of

questions and answers per topic. If we

cannot resolve questions immediately,

customers can contact our technical

hotline later on with reference to the

webinar.

Are the webinars still available later

on?

Yes, we record all of the webinars and

you can view them later. All participants

automatically receive the link.

And where do we go from here?

First off, as in the past, we have webi-

nars about once a month, alternating

in German and in English. In May / June,

we are discussing the topic TDM Form

Generator and in September / Octo-

ber, we will discuss the TDM Ordering

Module. In the meantime, other de-

partments use the webinar technolo-

gy for their own purposes, such as for

customer presentations or software

demonstrations.

Many webinar participants know him per-sonally: the longtime service technician and webinar leader, Waldemar Geweiler.

TDM INSIDE

The Difference between New and Used Tools

New and refurnished tools have different tool lifes - an im-

portant realization that the system takes into account. At

this point, there is no TDM software alternative that can

detect different tool states and assign that particular tool.

"We know down to the second, what the tool life of each

tool is and how much tool life we need to produce a part. 36

hours in advance, the system executes a resource check to

see how much tool life of a tool type is still in the system. If

that amount is under the required tool life, our tool assembly

automatically receives an order request and gets informed

exactly when the tool will be used."

The TDM software also helps to make sure tools are ready

for use. The presetters devices serve not only for the tool as-

sembly. They also receive numerous, predetermined char-

acteristics about the tools, which enable a plausibility check,

from TDM via an interface. This balance between the actual

data and the nominal data stored in TDM ensures that only

perfectly mounted tools enter the system. Kempf: "A key is-

sue for reliable production."

Conclusion: TDM manages and controls the tool crib at

Kempf. The focus is on supply security of the machine with

tools. TDM reports bottlenecks and problems well in ad-

vance so that countermeasures can be taken in a timely

manner. The order-oriented tooling and preparation outside

of the machines avoids follow up setup times. Thus, Stefan

Kempf achieved nearly 100 percent utilization of his ma-

chines despite an average of one new part a day.

[5]

[6] Everything under control: Stefan Kempf can perma-nently track the usage of his machines in real time.

[7] A gantry robot moves on rails over seven interlinked tool machines. It brings the necessary tools from the central crib and passes them to the machine's magazine. It takes back tools that are used up or no longer needed.

[7]

[6]

PRACTICE

The company, Norbert Kempf, is a medium-sized

contract manufacturer with 100 employees.

With its modern machine park of more than 20

machining centers, the medium-sized company

supplies renowned customers in the pneumatics,

hydraulics, automotive, construction machinery,

and prototyping. The range of workpieces consists

mainly of sophisticated, four-axis machined items

and assemblies.

www.norbertkempf.de

http://www.norbertkempf.de


The Networking of Three Worlds

PARTNERS

Industry 4.0 has led to a huge amount

of events, reports, and even research

projects. On the other hand, it is said

that German companies would sleep

through the digital revolution. How do

those go together?

Unfortunately, this is correct. It is excel-

lent that the German government has

taken this initiative. German engineer-

ing is indeed still a concept around the

world. However, politics have noticed

that many things are changing through

the ubiquitous digitization in the world,

which can cost Germany the lead-

ing role as an engineering country. The

pain threshold has not probably been

reached yet, especially for smaller and

medium-sized companies. Many think

that it will all carry on as it has before.

What is causing this reluctance in

companies?

In order to actually implement the

"smart factory," companies need a clear

idea about the advantages and the risks.

Without risk, there is no progress. Ger-

man companies have a hard time with

this realization. They want 100 percent

security, but must start with solutions

that are 50 or 60 percent secure. Take

cloud computing: There is no doubt that

this IT model means less security. How-

ever, you win something as well: Flexibil-

ity and Integration.

What can the "Industry 4.0 Collabora-

tion Lab“ change?

Many things, I hope. When I received the

call to come to Karlsruhe in 2003, I was

able to convince the university manage-

ment about the importance of innova-

tive teaching and research in the field of

engineering supported by modern infor-

mation and communication technolo-

gies. Thus, I was able to bring the Lifecy-

cle Engineering Solutions Center (LESC)

to life in 2008; and with it the newly

established Industry 4.0 Collaboration

Lab. The main idea is that a company

can bring their individual problems from

the field and we will work on a tangible

solution.

What role do the companies

involved play?

Through our collaboration partners like

Bechtle, SolidLine, or TDM Systems, we

meet the end users. We then offer them

the possibility with us that they will go

through specific scenarios virtually using

their data. After we have jointly identified

the problems, we advise them on how

they can fix it in the best and most cost

efficient way possible. Through learning

by doing, we demonstrate the practica-

bility of an individualize solution, in very

concrete terms.

Do the partners help with the

training?

Of course. The system houses are not

only the link to the economy, but also an

important supplier of the lab. We receive

software licenses from them for free or

at heavily reduced rates. With those, we

can get the students acclimated to IT

tools right in the first semester, which

is extremely important for Industry 4.0.

And these are not just powerful, large

systems, but pragmatic, on-the-mar-

ket engineering solutions. The students

should be able to intuitively deal with,

for example, CAD systems, from the be-

ginning. Here the focus is on using the

system and not on the system itself. The

system houses have understood this as

a service of the manufacturing sector

and provide added value, which is what

it is ultimately about in production.

How did you choose the partners?

I deliberately chose partners who move

between the three worlds that collide

within Industry 4.0: First, information

technology; second, manufacturing; and

third - not to be underestimated! – the

world of communication and collabora-

tion, so the social aspect of digital net-

working.

What did you with the latter?

Industry 4.0 means decentralization and

networking. It has been long preached

that integration is everything. Integrated

means that you have to take everything

in and think of everything. That prevents

flexibility. Today we know that we can no

longer build on that model due to com-

plexity, faster change frequencies, and

global competitive pressure. We must

move away from the centralized and

integrated solutions that have been pre-

viously propagated towards adaptability

and networking. That is exactly what I

like about TDM: They bring individualized

and networked solutions to the forefront

and move naturally between the manu-

facturing and IT worlds. They have ad-

vantages, because they already taken on

the networking roll.

Who will come out ehead with

Industry 4.0 – IT or manufacturing?

Much more important is the question of

how companies can realize the potential

of digitization. Because digitization rep-

resents the fusion of IT and manufactur-

ing, and the companies that operate in

an increasingly heterogeneous customer

landscape are already dependent on the

power of digitization.

Jivka Ovtcharova – Mediator Between the Worlds

Jivka Ovtcharova was born in Bulgaria and came to Germany 27

years ago. As a graduate engineer with a dual doctorate in me-

chanical engineering and information technology, the verbally

eloquent woman quickly worked her way to the forefront of in-

dustry and research: After successful industrial activity at GM /

Opel AG, she is now a professor and director of the Institute for

Information Management in Engineering (IMI) at the Karlsruhe

Institute of Technology (KIT). She is also the founder and direc-

tor of the Lifecycle Engineering Solutions Center (LESC) there as

well as the director at the Research Center for Information Tech-

nology in Karlsruhe (FZI). She thinks it is strange that, in Germa-

ny, she is still considered to be something exotic as a woman in

the engineering field who has the proud title of Prof. Dr.-Ing. Dr.

h. c.. In Eastern Europe, she was used to something else. "The

role of women in engineering here in Germany isn't anchored yet

in the minds of people and hasn't found wide acceptance," she

stated, irritated. It lacks flexible work models and success crite-

ria by which performance is measured. "Women get to the goal

in other ways. That is the crux of the matter.“

"SMEs Meet Research" is the motto of the "Industry 4.0 Collaboration Lab," which

opened in September 2014 at the Karlsruhe Institute of Technology (KIT). TDM

Systems is one of the industry partners, together with Bechtle IT system house

and SolidLine GmbH. Jivka Ovtcharova, Professor and Head of KIT, discusses the

objectives and competencies.


TDM User Day in early November at the Seco Tools Center of Excellence in Erkrath,

Germany focused on networking - not just technically, but also personally. 80 partic-

ipants took the opportunity to encourage the exchange of innovations related to tool

management and future topics such as Industry 4.0. TDMessage collected some of the

participants' comments.

Information and Exchange

Coordinator of CAD/CAM at Trumpf Werkzeugmaschinen GmbH + Co. KG, Hettingen, and Chairman of the 'TDM User Group':Ï liked the announcement of Global Line. We expect there will be significantly better

approval in our remote locations because of the improved performance. We store

over 30,000 tool assemblies and over 20,000 items in our data base. Users are no

longer willing to wait for information when you can get answers from Google in a

split second. In terms of Industry 4.0, Trumpf is at the forefront. With the "Internet

of Things," we have the problem that we also supply machines to remote locations,

where there is often a lack of internet bandwidth. And that happens not just in Asia.

We expect a tool data management system of the future to hold all of the manu-

facturer data and provide easy access. 2D and 3D drawings, parameters, feeds and

speeds, everything has to be available right away, without me having to sign on to

various portals."

AXEL KÖHLER

Responsible for mechanical manufacturing, tool management and tool dispensing at Liebherr-Werk Ehingen GmbH:"I'm here for the third time and always liked the event. By interacting with other TDM

users, you learn how others handle certain things. There are always great tips to be

had. I am very interested in the CAM interfaces, the crib management of tools and, of

course, the hosts, Seco Tools. The developments around the tool catalogues were also

interesting to me. I liked the platforms, because I no longer have to contact each manu-

facturer individually. That is sometimes tough to get the necessary tool data. The TDM

Fixture Management Module holds the most interest for us for crib management. The

TDM Tool Crib Module will be important in the future for driving the lifts in an automated

crib system, which is the direction we want to go in."

GEORG GRAB

Managing Director of Seco Tools GmbH:"We see the growing importance of digital solutions. Global processes create

a new level of networking between national economies. Those who are not

networked, fall behind. Whoever flees from this data linkage cuts themselves

off more and more from business opportunities. Therefore, we are launching

the portal 'My Pages' worldwide. It is available on all conceivable devices,

delivers everything about products and knowledge - the latest product infor-

mation, pricing, availability. You will be able to look up current and former

orders there and will have access to test reports. We store all of the nec-

essary data in a structured Product Lifecycle Management system. New

products without product information with it will no longer work in the future.

The topics advice, data, and overall technology exchange will gain immense

importance." DR.-ING. MICHAEL KLINGER

Group Leader of Turning and Milling Manufacturing at Gebr. Brasseler GmbH & Co. KG, Lemgo"At meetings like this, I think it is always interesting to hear views and experiences

from other companies. That is why the meet and greet the night before with its atmo-

sphere for open discussion is very important. I am also interested in the tour of the

company because it shows the practice. We are already dealing with Industry 4.0.

Management wants to see what each production machine does, when is it available,

when is something stuck in production? The problem is that we have many different

machines. How do we link them to one system? We are trying to influence our sup-

pliers to facilitate such connections. Each has their own interfaces and sees only their

own portion. Bringing them together is incredibly difficult, despite the existing data

bases and programs. Tool Data Management and Manufacturing Execution Systems

are building blocks towards Industry 4.0. Tapping information from the process in

order to optimize it; that will come in the next few years." RAINER DANGER

PRACTICE


Mr. Taillade, how long have you been

working with TDM Systems?

The partnership with TDM Systems

was established at the end of 2012. I

have been involved with the issue of

increasing efficiency through informa-

tion management throughout my en-

tire career though: In the '90s at IBM,

when they were just beginning to work

on the concept of computer integrated

manufacturing. And then for 14 years at

SANDVIK Coromant.

How did you discover your passion for

Tool Management?

As I was analyzing tool management

for a customer. While doing that, I found

out that the customer had not known

about many of the crucial aspects. With

tighter control of the tools, he was then

in the position to calculate the overall

machining costs and tooling costs per

workpiece.

How would you describe your job?

We help our customers to optimize

efficiency. Companies have to remain

competitive. Therefore, reducing costs

is essential in many respects. And Tool

"Helping Provide App ropriate Priority To Tool Management"

Lifecycle Management is a crucial com-

ponent of that.

What do you appreciate the most

about Tool Management?

The savings potential. Far too often, a

tool is "re-invented" unnecessarily. Or

you have to look for a tool in the first

place. This can be avoided with good

tool management.

What Is the greatest challenge in your

local market?

In France, a good portion of the budget

is channeled into ERP and CAD/CAM

programs. Other applications, on the

other hand, are often seen as only desir-

able, not as necessary. You have to first

help provide the appropriate priority to

tool management.

Can you share two things you would

like to see from TDM in the future?

I am looking forward to TDM Global

Line. This really is a new dimension of

software for companies that want to

exchange information across the globe.

And I am hoping for an expansion of

the actual installation of TDM on a lo-

René Taillade joins us this time in our Partner Series for questions and answers.

He is a TDM sales partner in France and firmly believes that the "gestion des out-

ils" (which means tool management in French) is much more than a desirable

complement to other programs.

PARTNERS

cal server in two ways: via a cloud data

base, where specific users at different

locations have access and via an indi-

vidual app on your smartphone.

What is your personal favorite topic?

In addition to the analysis of custom-

er processes, I offer practice-oriented

training to users and phone support for

technical questions, both in French.

René Taillade lives in Saint-Grégoire. He

can be reached by phone at +33 607

50 23 69 and by email at rene.taillade.

[email protected].

René TailladeLa Ramiere81350 Saint-Grégoire

France is a country dominated

by agriculture and industry. It is

especially world famous for wine

and cheese. The strongest indus-

tries are the automotive and air-

craft industries, which are loca-

ted mainly between Toulouse

and Bordeaux. In addition, the

growing energy sector is impor-

tant for France, as is the many

small metalworking businesses.

Paris

Lyon

Toulouse

Bordeaux

TDMessage 05-2015 21TDM Systems · www.tdmsystems.com20 TDMessage 05-2015 TDM Systems · www.tdmsystems.com

Overview of the Crib Reduces Machine DowntimesThe TDM Tool Crib Module organizes everything

that is in stock for tools and production resources.

Even tools that are located off-site are recorded.

By doing so, the module flexibly adapts itself to

each crib structure. TDMstoreasy, the intelligent

software for tool cabinets, supports this in praxis.

he TDM Tool Crib Module can map each phys-

ical crib and adapt itself to the customer," says

Regional Account Manager Andreas Maier from TDM

Systems, adding: “The software offers all of the

possibilities." At the same time, it integrates easily

in terms of Tool Lifecycle Management into higher

level systems.

Different Crib Systems

The positive aspect for the software's flexibility

is that it is able to cope with the most diverse crib

systems. Essentially, there is a distinction between

electromechanical and conventional systems; the

latter is also divided into "controlled" and "guided"

withdrawals. Controlled, individual withdrawals of

tools allows for what is known as vending machines,

similar to vending machines for food. Maier: "They

have experienced a boom in recent years and are

mainly used for round-the-clock supply in multi-shift

operation." Here, it depends on the shortest possible

access times.

In centralized tool cribs, it also operates with

paternoster and lift systems. They make use of the

expensive manufacturing area very well, because

they can be built all the way up to the ceiling of the

manufacturing hall. A combination of chaotic and

fixed location coded storage strategies, in turn, has

the advantage that the company can utilize the

available space in the most ideal manner possible. It

requires planned allocation so that one knows where

the tools, measuring and inspection equipment,

and fixtures are located. The cabinet management,

TDMstoreasy can control all types of cabinets and

can be coupled with the TDM Tool Crib Module or

used as a stand-alone system. As a result, con-

trolled tool dispensing and centralized evaluation for

all of the connected cabinets is possible.

Tool Management According to Status and

Location

The TDM Tool Crib Module maps all of the upstream

and downstream processes of a tool crib. TDM

itself forms the connection between the systems

(ERP and MES) and supports them with status

information about the actual status of the produc-

tion resources. The software records the status and

location for each tool. Thus, it is clear whether they

are tools that are new, used, or in need of repair. It

is also apparent whether an item is being ordered,

has been partially delivered, or has been delivered.

With the booking functions, the tools are booked on

the cost centers, for example on a machining center.

Moreover, it is always clear in which tool assembly,

individual items are installed and where exactly the

tools are.

Tool assemblies are either mounted or dismantled

and placed in storage for reverse bookings. The TDM

Crib Module supports the withdrawal process and

provides the necessary instructions automatically.

During disassembly, the employee is able to view

what is to be done with each part. Maier: "The TDM

module is practically the assistant who thinks along

with you."

TDM can summarize up to eight tool statuses under

one identification number, makes resource-oriented

planning possible, and eliminates bottleneck situ-

ations or even machine downtimes due to lack of

tools. The example of Norbert Kempf GmbH (Page

10) shows how well this works in practice.

Crib Management as Resource Planner for

Tool Lifecycle Management

Crib Management is an important basic function

in the overall Tool Lifecycle Management process.

Gathering the tool and production resource stocks

and giving information about their status and loca-

tion form a solid basis for planning tools, orders, and

machine uthilization. The TDM Tool Crib Module

even supports the ordering process or can handle

order management of the tools in combination with

the TDM Ordering Module. If the colleagues from the

NC programming also have access to the TDM Tool

Crib Module, then this information enables schedul-

ing of the available tools early on during the planning

phase. The tool variety does not grow exorbitant and

the available tools are used in the most optimal way

possible. In one sentence: The TDM Tool Crib Mod-

ule creates transparency and economic efficiency for

your tool organization.

[2]

[1]

[1] Stock locations can be edited in the TDM Tool Crib Module.

[2] Standard issue in the TDM Tool Crib Module.

T

SOFTWARE


Training in Tübingen

Training Date

TDM Base Module 06/08 - 06/10/15

TDM Tool Crib Module 06/11 - 06/12/15

TDM Form Generator 06/15 - 06/17/15

TDM System User 06/18 - 06/19/15

3D tool solids and parameters for CAM systems

06/22 - 06/24/15





3D tool solids and parameters for CAM systems

09/21 - 09/23/15





The training lessons take place in Tübingen,

Germany, language of teaching is German

We also offer custom training courses tailored

to your specific needs. These can be offered

in-house at your location or online.

Trade Shows/Events

Event Date

Automation Practices Forum "Mannlose Fertigung“, Kempten, Germany

06/16/15

MAPAL Dialog, Aalen, Germany

06/16 - 06/17/15

Turbine Technology Days 2015, Rorscha-cherberg, Switzerland

06/23 - 06/24/15

Companies meet Studies: Industrie 4.0 – supported by Tool Lifecycle Management, Karlsruhe, Germany

06/23/15

EMO, Milan, Italy 10/05 - 10/10/15

TDM User Day 2015 11/2015

We look forward to seeing you!

TDM INSIDE

Globalization of TDM Systems Service & Support CentersTDM users around the world make use of our software solutions in many different plants across the globe. They speak different languages and work in a wide range of time zones.For this reason, we are introducing our new concept of for regional service and support centers, which is now available at TDM Systems.

Service Center Asia / Pacific

in Kuala Lumpur, Malaysia

provided through TDM Partner

SDMK Sdn. Bhd.

+603 5191 2988

[email protected]

Service Times:

Mon. - Fri., 8:00 am to 5:00 pm

(local time, Kuala Lumpur)

Service Languages:

Chinese, English, Malay

Service Center Europe / Africa

in Tübingen, Germany

provided through TDM Systems GmbH

+49.7071.9492-800

[email protected]

Service Times:

Mon. - Fri., 8:00 am to 5:00 pm (CET)

Service Languages:

German, English, French, Italian

Service Center North America

in Chicago, USA

provided through TDM Systems, Inc.

and TDM Partner

+1 847.605-1269

[email protected]

Service Times:

Mon. - Fri., 8:00 am to 5:00 pm

(USA Central Time)

Service Languages:

English

Service Center South and Central America

in Florianopolis, Brazil

provided through TDM Partner AdeptMec

+55 48 3879 5579

[email protected]

Service Times:

Mon. - Fri., 8:00 am to 5:00 pm

(local time, São Paulo)

Service Languages:

Portuguese, Spanish, English

24 TDMessage 05-2015 TDM Systems · www.tdmsystems.com

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Everything Revolves around Tools - TDM Systems€¦ · 10 Everything Revolves around Tools ... That is why we talk about Tool Lifecycle Management today. ... It is nothing more than