During the production process, the existence and condition of tools, supporting components (holders & accessories), and assy are important aspects that must be carefully controlled. Tool ID comes as an internal web-based system that documents the entire tool lifecycle from initial registration, assembly, marking, use on the production line, to dismantle, regrind, or data deletion. The system is designed to support barcode and RFID-based production processes.
With a complex yet systematic system flow, Tool ID facilitates cross-plant coordination in managing tools, ensures traceability, and reduces the risk of data input errors. Tracking functions, activity logs, and PDF report features also help with technical and administrative documentation in the field.
Challenge
Before this system was implemented, the tool monitoring process in the production area was done manually. Operators must record tool counters, broken tool conditions, or tool replacement schedules directly on the CNC machine. Problems that arise in the field include:
- Counter data is not well controlled because it must be checked one by one on each machine.
- Tools often break before the maximum limit, but are not detected, causing increased operational costs.
- Manual recording process is time consuming and prone to human error.
- Tool storage is not clearly recorded, it is difficult to know the position of the tool, the amount of stock, and its usage history.
- Tool replacement errors in CNC machines that exceed the tolerance limit, potentially damaging the machine and reducing production accuracy.
Project Goal
This project aims to:
- Monitor the entire life process of tools, holders, and accessories on an updated and historical basis.
- Ensure data accuracy through barcode and RFID registration system.
- Improve efficiency in the process of setting, shipping, and tracking assy at each point (line, gate, plant).
- Provide troubleshooting and tool condition reports automatically.
- Facilitate tool dismantle and final evaluation (regrind, indexing, or spoiled).
With this system, companies have full control over tools from start to end of life, as well as structured data for engineering evaluation and production planning.
Features Offered
The main features implemented in this system include:
- Master Data : Manages important data such as Plant, Part, Line, Operator (OP), Holder Type, Tool Type, Accessories Type, Tolerance, Maker Tool, Maker Machine, as well as technical configurations such as Marking Program, BAT Program, and CNC IP. All this data becomes the relational foundation of the system as a whole.
- Registration : Records individual data for each tool, holder, and accessories. This data becomes the basis for future assy assembly processes.
- Assy Registration : Assembling tools, holders, and accessories into a single assy.
- Tool List : Displays a list of all tools that have been registered in the system, complete with their current status and relationship to the assy.
- Marking : Physical identification process through barcode/QR code on the tool or holder, to facilitate tracking and automatic reading in the system.
- Drawer Data : Record the position and status of the tool/assy in the storage drawer.
- Plan Setting : Planning tool settings based on production needs, including plan data and execution time.
- Setting : The preparation and completion stage of the assy assembly process from collection to final check before the assy enters ready-to-use status.
- RTU (Ready to Use) : Displays a tool or assy that has completed the setting process and is valid for use in production. Includes the measuring value of the Zoller and its barcode/RFID status.
- Gate : Facilitates assy entry and exit transactions from the production area to the tool center. Including the barcode/RFID status.
- Dismantle Assy : Dismantle an assy that has been used, while determining the status of the component: needs to be regrinded, cannot be reused (spoiled), can be reused (indexing). Linked to SPPCT process data (what assy, what tool.
- Users : Account settings and access rights based on user roles (user management) to ensure system security and control.
- Log : Keeps a history of user activities, including general activities and marking processes. Each user has their own log for audit and evaluation.
Result
Post implementation, the system has been capable:
- Lighter operator work, as there is no need to manually record or reset counters on the machine.
- Tool storage layout is more controlled, making it easier to search for tools based on storage location.
- Operational reports are faster to obtain because data can be accessed and filtered by date in the system.
- Minimal tool change errors thanks to direct tool identity validation in the system.
- Optimize the number of operators because most activities can be handled automatically by the application.