How can tool maintenance be better planned, carried out and documented?

Tools in forming technology are usually complex, high-precision equipment. Not only because of their functions (cutting, bending, drawing, embossing, calibrating), their designs (single, progressive, progressive, transfer tools) or processes (cold, hot, semi-hot forming). Their proper maintenance and servicing is just as complex. If a tool is not serviced regularly, unplanned machine downtimes can quickly occur. The situation is no less critical if tool damage occurs during production and the tool shop is informed too late. Predictive maintenance with digital interaction between toolmaking, production and planning play a decisive role.

In practice, toolmakers like to use simple Excel lists to manage and document tools, their uses, modules and spare parts. However, the functions of these lists are far from sufficient to do justice to the importance of the tools. This is where a digital solution for tool maintenance documentation offers clear advantages over paper-based or manual systems. Especially in terms of transparency, efficiency, safety and traceability.

The most important benefits of a digital maintenance solution for tools, including all components used, are

• Complete traceability
• Transparent tool statuses in real time
• Predictive maintenance through automated maintenance reminders
• Complete module management (change modules, inserts, bending stations, spare parts, etc.)
• More efficient collaboration between toolmaking, maintenance, production, planning and quality management
• Reliable analysis and optimization

Clear mapping of all tools of any complexity

The tool is created in the level of detail required for digital maintenance, including all tool components used. The master data of the tool, which is stored in the MES Software EMC, forms the basis for seamless documentation of the entire life cycle of a tool in the digital tool card. Tool life and maintenance can be assigned in detail to the frame, modules, assemblies and inserts. This guarantees continuous monitoring and optimization of the usage cycle of each tool.

The status of each tool is transparently available in real time

Which tool is ready for use? In maintenance? Defective? Which module is fitted?

Digital tool management provides real-time information on the current status of all tools, change modules, inserts, etc. This not only supports predictive maintenance, but also avoids unexpected downtimes due to worn cutting punches, for example.

Automated maintenance reminders

In the digital maintenance process, the tool is continuously monitored by the maintenance manager. At the end of a maintenance cycle or maintenance interval (strokes, machine running time, inserts/batches, time-based e.g. every 3 weeks), the tool shop is automatically informed that tool maintenance is due. Missed or overlooked maintenance is therefore a thing of the past.

Optimize processes between production and toolmaking …

… and thus simply increase machine running times. Everyone knows the current tool status and availability. In the event of a disruption in production due to tool damage, this is displayed directly on the dashboard in toolmaking. This makes it possible to react directly and immediately.

Once maintenance has been carried out, all measures, spare parts and times are documented cleanly and digitally and added to the digital life cycle card.

The digital tool card provides clarity

As in a maintenance log, all tool maintenance, machine maintenance and repairs are documented in the digital life cycle card of the MES Software EMC. The current status, availability and history of the tools are also stored in the digital tool card for tools (progressive tools, stamping and bending tools, drawing tools, rolling tools, etc.).

This provides easy access to all work carried out, repair and maintenance times and spare parts at any time. This enables optimum device and tool management.

Parts such as change modules or cutting inserts can also be tracked individually. Additional information such as articles and orders are also directly linked. Installed spare parts and their number as well as the stock can be traced exactly.

Manage spare parts smarter, monitor them cleanly and add them easily for maintenance

The EMC Spare Parts Management add-on module brings order and transparency to the spare parts inventory. This applies both to purchased spare parts and, in particular, to all parts that are manufactured directly in the company’s own tool shop. These are clearly stored and listed at all times. This eliminates the need for separate lists for the management and organization of spare parts.

The spare parts are configured individually according to their individual parameters and requirements:

• Minimum stock and inventory
• Spare part number and name
• Price
• Storage location
• Material
• etc.

Purchased spare parts are transferred directly from the ERP. Specially manufactured spare parts on site can be easily created in the system and configured according to the required parameters.

Stock levels, costs or storage locations can be easily managed at a glance. With digital spare parts management, it is always possible to reliably track which spare part is used where and how, or where it can be found and in what quantity. Automatic stock monitoring also means that you can always see exactly which spare parts are available.

In combination with the EMC Maintenance module, the spare parts used can be assigned directly to maintenance and servicing. To do this, simply select the required spare part from the list and add it to the relevant maintenance.

Intelligent analysis

Which tool inserts are responsible for production downtimes?
Which tools are maintenance-intensive?
Which modules fail frequently?
Which spare part is replaced most frequently?
How many benders are available for a production run?

Thanks to the complete, digital tool data, the toolmaking department can gain many insights for optimizing the tool and draw on them. This also includes tracking the use and wear of tools.

Conclusion

Many common methods such as separate lists, folders or notes for the management and maintenance of tools, exchange modules, inserts or spare parts are not sufficient to manage these cleanly, efficiently and transparently. Maintenance is easily forgotten, there is no clear module assignment or the lack of a meaningful data evaluation option.

Digital maintenance with real-time monitoring of tool status, predictive maintenance and automated notifications when maintenance is required make a significant contribution to increasing productivity and effectively avoiding machine downtime due to unplanned maintenance. Thanks to the clear documentation in the lifecycle card, the status of each tool can always be traced exactly. No more searching, no more laborious manual note-taking – everything can be viewed and accessed digitally.

Contact us

Do you have further questions about digital tool maintenance with our MES Software EMC or the implementation of your digital factory?
We will be happy to advise you and provide you with a personalized offer.

Simply call us on +49 7127 – 9231 10 or send us an email to info@ite-ms.de