Time-consuming and costly operations were the trigger for KAPP NILES to introduce digitisation into its machining and support processes.

Particular emphasis was placed on local integration but at the same time on the possibility of interfaces in customer systems. This ensures easy installation and integration into the existing Industry 4.0 landscape.

With the innovative software platform KN assist, the company has succeeded in finding a practical solution.

Take the set-up process to a new level

Set-up processes are time-consuming and involve the risk of errors. Since tooling is often used in a multilayered manner, tracking of the machined workpieces or the clamping cycles is difficult. 

The Kapp Niles Tool Management with guided changeover sequences at the plant guides the employee step by step through the set-up process. Within the sequences, the query for identification takes place. The machine recognises whether the component is correct for the grinding project, so that the geometric and process-relevant information is transmitted to the control system. The KN extender displays all relevant data of the stored components in a local database outside the machine. (See Figure 1)

The use and quality of tooling can be better planned via stored data, such as clamping and dressing cycles. 

Figure 1: KN extender manages component inventory

Transparency in production 

Together with its customers, Kapp Niles has sought a way to transparently present the Overall Equipment Effectiveness (OEE) key figures on the machine and on mobile terminals. The aim is to visualise the relevant KPIs (Key Performance Indicators) clearly and easily. 

With the Kapp Niles Production Monitoring System designed in this way, all connected machines can be displayed in a dashboard. 

Two views can be selected. (See Figure 2)

The machine overview shows the status of a machine. The individual machine view displays monitored status values, OEE key figures, relevant production data and the number of workpieces processed. The job history gives an overview of the most used grinding projects. The tooling dashboard is used in conjunction with the tool management system to visualise information about the tooling currently in use. The system also provides an overview of all pending service requests. New inquiries can also be triggered directly. 

Figure 2: Dashboard views

André Wetz, Product Manager at Kapp Niles, describes further advantages of the Production Monitoring System. "OEE key figures become easy to access and visualise. The optimized presentation of the KPIs and the most frequently used grinding projects specifically show potential in the production process and environment. The device-independent access to all relevant production data enables a transparent display at any time and from anywhere. Reaction times can thereby be minimized. Optimized communication leads to faster problem resolution and thus to shorter machine downtimes."

Real-time monitoring of the machining process

In order to meet the ever increasing quality requirements on the component and a high productivity, Kapp Niles has been looking for a solution for monitoring the grinding and dressing process. Here too, the company was in close contact with its customers in order to detect and avoid abnormalities already in the process.

This avoids an expensive 100% test afterwards. 

The Kapp Niles Process Monitoring System analyses the grinding and dressing process. The tool state is monitored and an evaluation of ripples or orders on the component is carried out. Based on the analysed data, the machining process is determined and visualized at the HMI. By means of adjustable limits, messages indicating deviations are issued at an early stage. An interface offers the possibility of providing data via a partial tracing to each manufactured workpiece. Data outside the machine can also be analysed in detail via export functions. (See Figure 3)

Figure 3: Export functions facilitate the analysis of machine data

Andreas Paatz, Head of Division Service and Tools at Kapp Niles, explains: "This system ensures a comprehensive examination of relevant features during the grinding and dressing process. As a result, errors or trends can be detected at an early stage and scrap and reworking percentage can be reduced. By monitoring the machining process, conclusions can also be drawn about the condition of the machine. A further advantage is that a removal of noisy workpieces after the machining process is made possible. By means of partial tracing, it is possible to detect critical workpieces also retroactively. Since the number of workpieces to be subsequently measured can be reduced, time and cost savings are achieved." 

From prevention to prediction 

If an unplanned machine shutdown occurs, it can have a large impact on various factors, such as productivity and on the adherence to deadlines, depending on the cause, and ultimately entail additional costs. The Kapp Niles Condition Monitoring System monitors the wear condition of the linear and rotary axes of the processing machine. By means of specific reference runs, the condition is recorded during operation of the machine. The degree of wear of the axes is visually shown on the HMI of the machine. In addition to a forecast of the service life, pre-set limits are used to output trends on the machine. Interfaces for the transmission of relevant data to further customer-specific production systems are available. Furthermore, the data can be supplied to each manufactured workpiece via a partial tracing. In analogy to the process monitoring system, the machine is equipped with additional sensors and a powerful IPC for evaluating the recorded data for monitoring the axes. (See Figure 4)

Figure 4: Powerful IPC is used for monitoring

Andreas Paatz: "The aim is to significantly reduce unplanned machine downtimes. This allows better planning of maintenance intervals and prevents unnecessary or premature replacement of machine components. This is due to the fact that fewer wear parts have to be kept in stock and can be ordered on a condition-based basis. The trend in modern production plants is towards condition-oriented maintenance and repair. Kapp Niles offers a powerful product here."

Make maintenance transparent 

Unforeseen maintenance work makes life difficult. Unpredictable production downtime can lead to reduced productivity and increased costs. If maintenance is necessary, missing information leads to additional expenditure. 

The KAPP NILES Maintenance Manager displays all maintenance plans and instructions in digital form. The database provides complete maintenance management with triggers, consumables, time expenditures, responsibilities and priorities. This enables usage-based maintenance. A traffic light function indicates when maintenance is due. All activities carried out are stored in the asset archive.

This archive (see Figure 5) is used to support the planning of maintenance processes.

Figure 5: Planning tool for maintenance processes

Authors

Andreas Paatz, Head of Division Service and Tools at KAPP NILES
André Wetz, Product Manager at KAPP NILES

Contact external for publication

KAPP NILES GmbH & Co. KG
Tel.: +49 (0)9561 / 866-0
info@kapp-niles.com
www.kapp-niles.com

Contact INTERNAL, ONLY FOR EDITORIAL QUERIES

Carola Rehder, Manager, Communication and Marketing at Kapp Niles
Callenberger Str. 52, 96540 Coburg
Tel.: +49 (0)9561 / 866-1250
carola.rehder@kapp-niles.com