ʺA positive shift is underway, with more manufacturers embracing automation… Some are even exploring visual inspection systems to identify incorrect part placement. So, it is not just about probing anymore, it is also about expanding into broader areas of shop floor intelligence,” says Rashmi Gururajrao, Co-Founder Director, Manleo Designs.
Neha Basudkar Ghate
Q: What are some common misconceptions you have seen in the industry about CNC probing systems, particularly around cost, ease of use, serviceability, and their impact on cycle time and shop floor efficiency?
A: We often encounter a few common misconceptions about CNC probing systems. For instance, many people think that probing systems are always expensive. In reality, affordable options, which can be integrated step by step, are available. Another misconception is that CNC probing systems are only for highly skilled operators. In reality, modern probing systems are designed to be user friendly. So, even operators with limited experience can operate them. Service support is another common concern. Many are sceptical about whether they will have support staff to help them resolve their technical queries. There is also a misconception that probing increases cycle time. While it is true that probing may add a few seconds to the cycle time, what is often overlooked is how much it reduces rework and scrap. If a small time investment in probing can lead to 50% less rework, then that is a huge gain in terms of saving time, raw material, and cost.
Despite all these benefits, the adoption rate for probing systems in India is still very low. For every 100 Vertical Machining Centers (VMCs) sold, only one or two may come with a probing system. While the adoption rate is slightly better with imported machines or large OEMs who have audit mandates, among MSMEs, the adoption rate is limited. The reason for this gap is the lack of awareness. To create awareness, solution providers, machine builders, and users need to be proactive. We have even proposed forming a community to promote the use of probing systems across brands. The goal is not just to sell a product, but to get more people to see the value of probing systems on their shop floors. If machine tool builders start educating customers and making probing systems a standard offering, just like other accessories, it could make a big difference.
Q: How critical is sub-micron repeatability in high-precision industries like die and mould? What broader technological, educational, and systemic challenges are preventing Indian manufacturers from consistently achieving that level of accuracy?
A: Recently, I had read on LinkedIn about how Vietnam, despite being much smaller than India in terms of size and population, is doing far better when it comes to manufacturing exports. Around 20% of Vietnam’s GDP comes from manufacturing, compared to just 13% in India. This is something we need to reflect on. Vietnam has taken better advantage of the China+1 strategy, something that should have ideally benefited India more.
So, when countries like the US or Japan outsource their precision machining jobs, we need to consider the following:
– Is India their first choice, or are we still seen as a destination for jobs that are 50 microns and above?
– How many of us in the industry are working within 10-micron or even 5-micron tolerances?
When we look at the root cause, it often comes down to confidence, whether global customers believe we have the capability and setup to deliver within 10 microns. Probing is a big part of that setup. If we are not using the right probing systems, we cannot guarantee repeatability or accuracy. That is where we fall short.
In terms of technology adoption. China uses around 60,000 to 75,000 probes every year, while India uses around 10,000 probes annually. Why is this gap in technology usage so wide? There are multiple reasons for this. One is the lack of awareness about the value probing systems bring. Another is accessibility, whether it is easy to integrate probes, get service, or support. If these challenges are addressed better, more people would feel confident about adopting probing technology. At the grassroots level, education or training can also be considered a key factor. Students in training institutes will understand the importance of probing systems if they are exposed during the early stages of academics. But the main challenge here is affordability. Basic imported probes cost around INR2.5 lakhs. During training, if something goes wrong, the training institutes might not be able to bear the replacement cost. These are some of the practical issues they face.
Sub-micron repeatability is critical, especially in industries like die and mould or tooling. But to achieve that, we need to build the right ecosystem, where probing is better understood, easier to adopt, and supported from education to execution.
Q: Despite strong technical capabilities, what operational or human factors are holding back die and mould manufacturers from consistently achieving high precision results? How do tooling errors, affordability, and shop floor adoption contribute to this challenge?
A: One of the practical challenges in achieving consistent precision in die and mould manufacturing lies in the actual implementation and adoption of systems on the shop floor. Even when owners invest in advanced systems, if the shop floor staff do not use them, it is a wasted investment. Another recurring issue in this sector is the use of the wrong tools. For instance, using an end mill instead of a ball-nose cutter, or erroneously loading an 8mm tool instead of a 6mm one. These mistakes not only impact the bottom line, they also damage the shop’s reputation and its ability to deliver high-precision work. The industry does not lack technical capability. In fact, many TAGMA members, for example, are already producing sub-5 micron moulds at scale. Their challenge is mostly related to affordability and operator-level adoption.
Q: From your perspective, what are the critical gaps that machine shops need to address to move from semi-automated setups to fully autonomous systems, while staying cost-effective and flexible in production?
A: In my opinion, shop floors cannot completely automate or become 100% Industry 4.0-compliant unless the industry stops relying on manual work and human judgment and starts using technology effectively.
Currently, the automation adopted on shop floors is restricted to the surface level. For instance, many setups are focused on monitoring operator efficiency and concentrate on factors like how long someone was at the machine or how long the machine was idle. However, we first need to understand why there was downtime in the first place. One cannot always blame the operator in such situations. We need to consider factors like the operator probably did not have the right tools or access to the necessary technology to work effectively.
To transition from semi-automated cells to fully autonomous systems, the workforce must be empowered with the right technologies and support. Only then can automation and Industry 4.0 become a reality, while still being cost-effective and flexible.
Q: How can probing and measurement automation in VMCs help detect process issues early in tooling and job alignment and contribute to better root cause analysis, reduced rework, and overall process stability?
A: For VMCs, you need to control two key variables: the job or workpiece and the tools you are using. Probes help you get accurate starting data for both. If the starting point is correct, then it is most likely to finish the job as per the customer’s specifications. Think of it as GPS; it guides you from the starting point with the right references.
We also have systems where, with a small investment, users can perform in-machine inspections using the same probe. These systems don’t require added software or incur additional costs. They can check if the job is done correctly while it is still in the machine. Some setups even allow users to generate a report showing where rework or rejection might occur, so they can fix it before unloading the part.
This is a big time-saver compared to the current process, where the component is offloaded, taken to the CMM, found faulty, and then brought back for rework. If you detect issues before taking the component off, it can greatly improve productivity.
Also, on the tooling side, when you are using many tools, let’s say 20 for one job, each one has a different length. If you use an automatic system to measure tool offsets, you can prevent a lot of rework or rejection caused by broken, damaged, or incorrect tools. Overall, probing helps you complete jobs on time and within specification, which improves process stability.
Q: What specific challenges make in-machine metrology essential for the die and mould industry, especially considering long machining times, expensive materials like Inconel and Titanium, and the shift toward tighter tolerances and reduced blue matching?
A: In-machine metrology is critical in the die and mould industry because the machining cycles are long and complex. Unlike mass production, where parts are made quickly, a single medium-sized mould can run for three to four days, while a complex mould can take up to a month or two. If a mistake is discovered only after offloading the mould, it causes major rework and delays and incurs additional expenditures. The larger and more complex the mould, the harder it becomes to manage rework, especially with the time and effort involved in transporting and resetting the mould in the machine.
The situation gets even more complex if expensive materials like high-grade steel, Inconel, or Titanium are used. If a mould worth INR1.5 to 2 lakh gets rejected, it could mean the loss of an entire month’s income for a small machine shop. That is why early error detection, while the part is still in the machine, is important in this industry.
Another major issue in die and mould is ‘blue matching’, where two mould halves need to match perfectly. Shops often use a blue dye to visually check this match, and if there is a mismatch, they resort to manual hammering and adjustment. After adopting tool probes, many of our die and mould customers have told us that blue matching is no longer a concern. The number of machining passes required has reduced drastically; they are now achieving results in the first or second pass instead of the fourth or fifth. This not only saves a lot of time but also gives them the confidence that the mould will come out right the first time.
Q: With increasing complexity in die and mould geometries, how can machine tool builders support manufacturers in adopting probing, tool setting, and post-processing inspection as part of their standard strategy?
A: When it comes to probing and post-processing inspection, machine tool builders have a crucial role to play in encouraging its adoption. They can accomplish this by making basic probing and tool setting systems a standard part of the machine package, especially for die and mould customers. If a machine is delivered with a probe and tool setter installed, then customers are more likely to use the technology. This is because it will eliminate the need for them to make a separate investment, as probing will become a part of the machine tool builders’ ecosystem from the start.
Q: Are there any new trends coming up in the probing industry when it comes to the die and mould sector or the tooling industry?
A: In the die and mould industry, there is a shift towards automation. Manufacturers are gradually moving away from manual probing systems and adopting automated probes along with in-machine inspection reports. This trend is also evident among large die and mould makers. A positive shift is underway, with more manufacturers embracing automation and reducing dependence on human judgment. Some are even exploring visual inspection systems to identify incorrect part placement. So, it is not just about probing anymore, it is also about expanding into broader areas of shop floor intelligence.
(This interview was earlier taken in TAGMA Times magazine)
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