“Preventive maintenance is not yet an established technology when it comes to machine tools. The current situation is that it is difficult to predict because many factors are involved,” says Tadashi Kasahara – General Manager, Advanced Robotics & Digitalization Business Unit MAKINO ASIA Pte Ltd
Neha Basudkar Ghate
Q. How are advancements in robotics and digitalization transforming the production process in die and mould manufacturing, especially regarding precision and cycle time?
Advances in digitalization, such as high-speed mass processing, have led to the development of high-speed reading and smoothing of NC programs consisting of minute blocks. Compared to the early days, processing time has been significantly reduced. Advances in sensing and digital technology have also made it possible to correct factors related to accuracy. It achieves high-precision machining results even during long machining times.
Q. What are the key challenges in integrating multi-axis control systems and on-machine measurement technologies into existing die and mould manufacturing workflows?
As for 4- and 5-axis control systems with three or more axes, progress has been made in terms of shortening setup times by indexing and machining. On-machine measurement technology basically began with measuring the reference position during setup. As the precision requirements for moulds become stricter, there is a growing demand for on-machine in-process measurements and inspection measurements. On-machine measurement with precision requirements of better than 5 μm still faces challenges in terms of accuracy and differences with CMM.
Q. How can automation help address labour skill shortages in the die and mould industry while maintaining or improving product quality?
Efficiency can be achieved by establishing the correct process, standardizing it, and then automating it. It allows the entire system to be up and running with minimal labour. However, the mould will be processed as a single item. The difficulty lies in the fact that it is always the first time we process a case. We look forward to the realization of applying AI to derive optimal solutions based on experience with similar processes. If this becomes possible, we believe it will be possible to manufacture with minimal labour, approaching the level of mass-produced parts processing.
Q. Could you share insight on how digital twins and FA management software contribute to predictive maintenance and process optimisation in tooling manufacturing?
Preventive maintenance is not yet an established technology when it comes to machine tools. The current situation is that it is difficult to predict because many factors are involved. In the future, we believe that predictions will be possible by collecting and analysing operational data from machine tools equipped with many sensors all over the world. FA management software helps optimize processes. Where is the bottleneck in this system? It is possible to infer this from past data. For example, it is possible to estimate the amount of wear on the cutting edge of a tool from past data.
Q. In your experience, what role does enhanced human-machine interaction, sutch as voice-enabled machining or intuitive control interfaces, play in increasing operational efficiency and reduction errors?
I think the trend towards automation and labour-saving will accelerate in manufacturing sites. Once FA software is in charge of management, there will be no need for voice support or even intuitive machine operation. I believe that this is the kind of world we will live in.
Q. How does the intersection of robotics and digitalization facilitate smart factory concepts in die and mould production, and what benefits can manufacturing expect?
As mentioned above, moulds are processed into a single item. This is a major barrier to automation. You can’t recreate the exact same experience. I believe that one way to compensate for this is to use highly flexible technology such as AI to replace people by making estimates and inferences.
Q. What innovation in machining technology are enabling faster prototyping and more agile production cycles for complex die and mould components?
We believe that future machine tools will become censored machines equipped with a large number of sensors. We believe that we will be able to read the processing status from a large amount of data and make improvements. I believe we are entering an era where sensors and the analysis of large amounts of data will be used to determine the quality of processes.
Q. How important is interoperability between robots, machine tools, and digital systems in creating flexible and scalable automation solutions for tooling manufacturers?
The robot’s versatility allows it to efficiently transport parts to multiple process machines, such as in mould manufacturing. We believe that by combining FA management and censored machines, we will gradually achieve greater efficiency.
Q. How can industry stakeholder’s best prepare their workforce and infrastructure to adopt advanced robotics and digitalization technologies successfully?
There is a growing demand for higher precision in moulds, primarily due to requests from the EMS industry. In some cases, this may be at a level that cannot be reached using existing methods. Additionally, increasingly complex machines and processes make it difficult for operators to intervene.
I believe it is necessary for machines to be equipped with technology that uses a variety of sensors to identify and solve problems.
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