When visiting the halls of Schubert Fertigungstechnik GmbH, the large number of robots and automation solutions on the machines immediately catches the eye. The company is not a series manufacturer; typical batch sizes range from three to ten units and are sometimes fewer than 100 pieces. ‘We have been working for a long time to get 18 to 22 hours of autonomous machine time. This means we can run the machines around the clock without having to ask our employees to work night shifts,’ explains Jens Grieser, the managing director responsible for the technical division. ‘Ideally, we would make early and late shifts as unnecessary as possible. But we need to ensure the same high level of quality at all times.’

With this in mind, Erhard Strobel, sales engineer at Blum-Novotest, found a receptive audience in Bartholomä with FormControl X. Schubert was very interested in the BLUM software, a client server-based solution for the automated measurement and evaluation of machining processes. Ultimately four variants of a part are manufactured on one machine, with around 60 parts per variant and a cycle time of between 10 and 40 minutes per part – but only if the machines are running at full capacity. This means it is very important to keep an eye on quality, also during unmanned shifts. Thanks to FormControl X, specialists can be sure that all measured values are upheld. The advantage of measurement being performed during the process is that it is clear when a measured value begins to drift. Action can be taken long before the tolerance range is exceeded. It goes without saying that this is especially true for broken tool edges.

FormControl X is a client server-based software solution for the automated measurement and evaluation of machining processes. BLUM developed the software from scratch based on the tried-and-test FormControl software with a particular focus on the automation of measurement processes. A major advantage of the client server architecture is that the data in the FormControl X database can be accessed from multiple workstations or machines. This allows users to easily create complex measuring programs at their office workstations or review the measured values taken during the previous night. The operator can monitor the tolerance fluctuations of all measured values on a laptop near the machine. The display is generally very simple and can be viewed on a PC, laptop or tablet in a standard web browser.

The flexible options that can be used to influence the machine with FormControl X are very interesting: In one case, for instance, the manufacturing process is only stopped when the same deviation is measured on two parts in a row. This rules out the possibility of a chip adhering to the measuring point during the first measurement. ‘For example, it is possible to measure every fifth part. In the event of an outlier, instead of waiting to measure the next five parts, the machine immediately starts measuring again during the next machining process to rule out a chip at the measuring point,’ explains Erhard Strobel. ‘Only then does the program decide, based on the specifications, whether the next part will be machined, whether the machine will interrupt machining or whether it will switch to the production of another part using different tools.’

The Fanuc Robodrill machining centres are mainly used to manufacture components for tool changers for Schubert packaging machines. For instance, these tools can hold boxes into which a robot places chocolates. If a different package size or shape is required, the tool can be changed and the packaging line automatically switched over. Several pneumatically operated pistons with an H7 fit work in parallel in these tool changers. The bore holes in which the pistons run must be made very precisely and have to parallel to each other with the correct diameter. Measuring every part produced is necessary to ensure reliable operation later on. This is because a stoppage in a packaging machine can be extremely expensive, for instance with the chocolate production processes mentioned above: If the packaging line stops, the production of the sweets must also be shut down because the liquid chocolate and other ingredients will solidify and go bad. In addition, the pre-assembly processes at Schubert are synchronised, which means that deliveries must be made at very short notice. So a problem on the machine also affects processes at the parent company, which accounts for around 70 percent of orders. That is why the accuracy of the measurements in the machine was checked continuously during the beta test prior to the purchase of FormControl X – the deviations were in the range of a few thousandths of a millimetre.

The designers of the packaging machines specify dimensions that are crucial for proper functionality and have to be checked during production. The NC programs are then created in Bartholomä, and the measurement subroutines are incorporated at the appropriate points. ‘We work together here: We, the employees working on the machine, are responsible for quality, which is why we decide together with the NC programmers which dimensions are recorded with the BLUM measurement cycles and stored in FormControl X,’ explains Markus Maier, who supervises the RobodrillPlus Big K systems. ‘This also gives us the knowledge we need to understand the measurements and make improvements.’

During the introduction phase of FormControl X, we stayed in very close contact with the BLUM specialists: In addition to the dedicated support of the programmers during beta testing, Schubert was also impressed by the excellent training. Currently, a new part only needs to be programmed every two or three weeks in Bartholomä, but the employees still have a good experience with the software because it is very intuitive. FormControl X also helps them focus more on their actual work. For instance, in the past, time had to be spent in the morning checking the dimensional accuracy of the components manufactured overnight. Now a glance at the screen is all it takes: The graphical display of the FormControl X web client shows whether the tolerances have been upheld. This allows employees to react immediately or continue production straight away.

All dimensions with tolerances of less than a tenth of a millimetre are now measured automatically, as are shape and position tolerances. These are important because many parts are machined in two clamping operations, which means the position of the second machining process depends on the surfaces produced in the first clamping operation. This is another reason why FormControl X brings major improvements to everyday work processes: ‘The software takes care of the measuring tasks for me because they are automated. This means I can concentrate more on my actual work,’ reports Markus Maier. ‘Working on the machine is also more relaxed because the process is transparent and we always know where we are in terms of quality – that’s very reassuring. What’s more, I no longer have to work in shifts since I can finish my work during normal hours – that’s a huge advantage for me!’

The number of employees at Schubert Fertigungstechnik who are being ‘freed’ from shift work could rise soon: Thanks to the positive experiences at the Fanuc centres, there are plans to use FormControl X on many other machines with the aim of increasing productivity. After all, BLUM software is an important part of the automation of machining processes and is playing a decisive role in achieving a very high level of automation in Bartholomä.

FormControl X has proven its worth and entrenched itself at Schubert Fertigungstechnik: ‘For each production batch, the first and last measurement logs are printed out and filed, and apart from that, all measurements are available in the FormControl database. ‘This is useful for assessing the tool service life,‘ summarises Jens Grieser. ’And it’s also reassuring for me to be able to see where we are in terms of quality at any time. Of course, the machines and the range of parts have to be just right so we can get the most out of the software – and that’s the case for us.’

Cutting tool specialist Sandvik Coromant has launched the CoroMill® Plura barrel, a new family of optimised solid end mills designed specifically for profiling applications. This new solution provides high process security, significant productivity gains and cycle time reductions of up to 90%, making it particularly suitable for the aerospace industry and other high-demand sectors.

Marking a unique addition to a comprehensive range of end mill solutions for ISO S profiling applications, including CoroMill® Plura ball nose, CoroMill® Plura lollipop and CoroMill® Plura conical ball nose, CoroMill® Plura barrel offers a new machining principal for profiling tools. Several key features make it the ideal complement to the range, such as a unique one-radius barrel form with up to six optimized flutes.

The CoroMill® Plura barrel offers substantial advantages over traditional ball nose machining strategies by utilising an increased contact radius. This design enables up to a 90% reduction in cycle times by increasing the step-over, which not only enhances machining efficiency by significantly increasing the surface removal rate (SRR) but also ensures exceptional surface quality.

The optimised barrel design results in a reduced cusp height between passes, leading to superior surface finishes and lower surface roughness. Despite generating higher forces, the stability and process reliability of barrel end mills make them an ideal choice for achieving precise finishes in demanding profiling applications.

“CoroMill® Plura barrel excels in applications requiring precision and superior surface quality,” said Liam Haglington, Product Manager for Solid Carbide Milling Tools at Sandvik Coromant. “Its large cutting edge radius enables increased step-over and reduced cycle times, boosting productivity during high-volume material removal. The large barrel radius makes it ideal for machining large, complex contours and 3D shapes, while minimising scalloping for shallow depths of cut.

“This tool is particularly suited to demanding applications like aerospace, where components such as engine blisks involve complex geometries and challenging materials. It also enhances profiling in other high-demand sectors like medical, oil and gas and power generation.”

The tool is available with Sandvik Coromant internally developed material-specific grades, including T2CH for titanium alloys and R2AH for heat-resistant superalloys (HRSA), both delivered by Sandvik Coromant’s Zertivo® 2.0 PVD coating for improved durability and wear resistance. For customers with specific size and diameter requirements, the tool can be customised through Sandvik Coromant’s Tailor Made® service, while the CoroPlus® Tool Guide platform can further aid application needs with expert tooling advice.

“Results achieved thus far demonstrate the tool’s reliability and productivity,” added Haglington. “For a customer machining an inconel engine blisk, a machining strategy with CoroMill® Plura barrel resulted in a cycle-time reduction of greater than 40%. Here, reaching 88 minutes of operation, a 50% increase in tool life was achieved compared to the customer’s existing solution. In another case, this time with a titanium blisk, a customer saved over 90 minutes of machining time when using this product over a competitor’s conical ball nose solution.”

In line with its commitment to sustainability, Sandvik Coromant also offers a comprehensive recycling program for worn-out carbide tools, including CoroMill® Plura barrel and other advanced milling solutions. This service allows customers to return used tools for responsible recycling, reducing industrial waste and conserving critical materials like tungsten and cobalt. By participating, manufacturers not only contribute to environmental sustainability but also benefit from a more resource-efficient and cost-effective production process.

Representatives from machine tool associations – whose manufacturers account for more than 80% of the global machine tool production, gathered at the world’s leading trade fair for production technology to demonstrate their resilience and strength in the face of a wide range of global challenges. Despite a stable outlook for 2023, projections for the global machine tool industry are tempered by various international and economic challenges. Building on the collective strength of the sector, collaboration, innovation and adaptability will remain key as the industry continues to navigate this evolving landscape.

“At a time of profound political and economic uncertainty, the promotion of international cooperation is imperative” underlined Dr Heinz Jürgen Prokop, CECIMO’s President, in his opening remarks at the CECIMO’s Press Conference at EMO Hannover 2023. The event united machine tool industry leaders from the United States, China, Japan and Europe.

Mr Marcus Burton, Chairman of CECIMO’s Economic Committee, highlighted CECIMO’s commitment not only to lobbying for favourable conditions for the sector, but also to fostering international cooperation with machine tool associations around the world. In that context, he also unveiled key insights from CECIMO’s recently published Global Machine Tool Report 2022, which could not have been produced without such cooperation. Based on the latest database update, Mr Burton highlighted that Global MT (machine tools) production reached a level of 79.2 billion EUR in 2022, reflecting an annual production increase of 11.9%. In the same year, MT production in the CECIMO countries recorded an increase in MT production of 12.8% and, with a level of 25.3 billion EUR, CECIMO maintained its share of 32% of global MT production. On the consumption side, CECIMO countries accounted for almost a quarter of global MT consumption, with a total value of around 18.7 billion EUR in 2022 (+25% compared to 2021).

During his presentation, Mr Burton, also revealed the latest estimates for 2023 for global and European MT production. While he highlighted that MT production in the CECIMO countries is expected to grow by around 5.5% to reach a level of almost 27 billion EUR in 2023, global MT production is expected to remain more stable, slightly below the 2022 level. In his concluding remarks, he pointed out that “In light of current developments, we have slightly downgraded our expectations. Nevertheless, we remain optimistic about the positive growth in European MT production in 2023 and our initial indications for 2024 are positive“. However, he also highlighted the significant challenges on the horizon, including the headwinds of slowing global economic growth, rising interest rates and geopolitical shifts resulting from the ongoing conflict in Ukraine. These factors collectively inject a notable degree of uncertainty into the short-term demand landscape for the machine tool industry.

In reference to the Chinese machine tools sector, Mr Mao Yufeng, President of China Machine Tool & Tool Builders’ Association (CMTBA), pointed out that “from January to July 2023, sales of metal cutting machines dropped by 4.3% to 10.76 billion USD compared to last year. On the other hand, sales of metal forming machines went up by 6.9% to 6.16 billion USD”. He also stated that 2023 has witnessed heightened endeavours in industrial restructuring and shifts within China’s machine tool consumer market. Among others, this includes a decline in overall automobile production, but a notable increase in the use of new energy vehicles. In addition to shifts in consumer markets, he highlighted several significant challenges that contribute to the uncertainty surrounding the outlook for the machine tool sector. These challenges include a fragile economic recovery, persistent inflation, financial market instability and increasing debt pressures.

In light of Japanese metal cutting MT sector, Mr Kazuo Yuhara, President of Japan’s Machine Tool Builders’ Association (JMTBA) highlights remarkable growth for the Japanese metal cutting machine tools sector in 2022. Total orders surged to a record-breaking 1,759.6 billion yen, increased by 14.2% from the previous year. Production of metal-cutting machine tools increased by 20.5% in 2022 over the previous year to 1,078.8 billion yen, with a strong growth trend in both exports and imports levels. Looking at the most recent period (January-July 2023), he noted the decline in order volumes for metal-cutting machine tools, but highlighted positive expectations for the impact on demand of investments in green, digital and resilience-related areas.

Looking at the American machine tools industry, Mr Douglas K. Woods, President of AMT – the Association for Manufacturing Technology in the USA, emphasised continued stable conditions for the American machine tools industry in 2023 and 2024, following a year of near average consumption, totalling 9.6 billion in 2022 USD. In 2023, the effects of the tightening of US monetary policy become apparent, leading to a slight decline in machine tool consumption, he added. However, indicators for 2024 suggest a recovery in machine tool production and imports, while exports stabilise, leading to an increase in consumption.

Winfried Weiland, Marketing Manager at Blum-Novotest GmbH, explains: “At this year’s EMO, everything at our booth will have to do with automation. This topic is often primarily associated with robotic solutions that insert raw parts into machine tools and remove the workpiece after machining. We at Blum-Novotest, however, take a more holistic approach; after all, the goal is to produce as many good parts as possible in the shortest possible time. That is why we will be demonstrating how intelligent production measurement technology combined with modern robot technology enables machining in a closed control loop live at our booth at the EMO”.

The highlight of this year’s presentation will be the FormControl X measuring and automation software, which will be shown interacting with a cobot at the BLUM booth. This is a clever solution for machining centres for machine-integrated quality control of workpieces in series production. The software enables automated monitoring of machining processes in line with the principle of statistical process control (SPC). The process is managed based on the recorded measured values and previously defined warning and control limits. To make sure that this also works perfectly in unmanned operation and in cooperation with robot solutions, FormControl X offers a clever approach with its alignment function. This feature detects the current workpiece position and alignment right after clamping and automatically adjusts the reference points of the machining program to the actual position of the workpiece. This also makes reliable automated machining of parts with small allowances possible. FormControl X also prepares the recorded data in graphic form. It can then be visualised and evaluated by the user using the web browsers of any end devices. FormControl X accelerates manufacturing processes and makes them more transparent, and the quality and manufacturing costs of the finished workpieces are optimised.

The second software solution that BLUM will present at the EMO is the latest version of the LC-VISION measuring and visualisation software. The application, which was developed specially for the laser measurement systems from BLUM, has been adapted even more closely to the needs of users and its usability has also been improved. For instance, the free standard scope has been expanded to include the “ToolControl” and “Stability” functions. ToolControl is an intuitive application which even users without NC programming knowledge can use to quickly and easily generate measuring sequences for the most common measuring tasks. The user can visualise measuring sequences for tool length and radius, including the tool-specific wear limits, directly on the control screen and take appropriate action. The stability function is used to determine the thermally stable spindle state for high-precision machining, to name just one example. If a machine is in the warm-up phase, the spindle elongation is measured at speed and the length value in the tool memory is updated after the thermally stable state is reached. For ambitious measuring tasks, there are also optional technology cycles available such as “ToolControl Advanced” or “SpindleControl”.

“The third highlight of the trade fair, the new TWIN technology, makes it possible to simultaneously operate two BLUM tool or workpiece probes with only one radio receiver. This technology is mainly used in dual-spindle machines, whereby a cycle time reduction of up to 50% can be achieved due to the omission of a second probing movement. The BRC technology used ensures secure transmission, and no line of sight to the receiver is required,” Weiland concludes.

The sector is performing well with regard to sustainability: 50% of the companies with UCIMU mark state that in the next three years they are planning to issue a Sustainability Report (48%) and work out a Strategic Plan (54%). The short-middle term goals for the enterprises of the sector are an increased formalisation of policies and processes and the carrying-out of targeted communication initiatives.

This afternoon, during a meeting attended by enterprises, the credit world, institutions and press, the first Sustainability Report dedicated to the machine tool sector was presented. It was carried out by UCIMU-SISTEMI PER PRODURRE, the Italian machine tools, robots and automation systems manufacturers’ association, in cooperation with ALTIS, Graduate School Business & Society of the Catholic University of Sacred Heart.

“Sustainability is an extremely profitable field for companies, because it does not only allow to improve the relations with one’s own stakeholders, but it also offers them an opportunity of reinventing and realigning themselves with the European regulatory framework, which emphasizes the importance of a wider use of good ESG practises. With regard to this Report, we can affirm that a good number of ESG practises have already been introduced. In the field of capital goods, UCIMU-SISTEMI PER PRODURRE is the first association, in Italy and in Europe, to carry out a Sustainability Report of the sector. This outcome undoubtedly makes us very proud. The next step will be to formalise and extend it to a larger number of enterprises. For this purpose, UCIMU will continue its activity of education & training and support for its associate member companies started over the last few years”, pointed out Barbara Colombo, president of UCIMU-SISTEMI PER PRODURRE, who opened the work sessions together with Vito Moramarco, Director of ALTIS Catholic University.

Stella Gubelli, Managing Director of ALTIS Advisory Srl, a Spin-off and Benefit Corporation of the Catholic University of Sacred Heart, described the contents and the main aspects emerged from the study: “The project developed with UCIMU is intended to encourage the start of improvement paths in the associate member companies, based on an objective ESG evaluation and aimed at sustainability areas that are important for the sector. We think that this is the most effective way to support the enterprises in facing challenges and seizing opportunities”.

The round table, moderated by Mauro Bellini, Managing Director of ESG360.it, included the experiences of Barbara Colombo, Managing Director of Ficep, Massimo Carboniero, Managing Director and Co-owner of Omera, and Andrea Portosa, Purchasing Manager of Rosa Ermando, as representatives of three enterprises of the sector that carried out their first sustainability report; Natale Schettini, Head of Credit Governance, Banco BPM, Carolina Lonetti, Chief Export Finance & Internationalization Officer of SIMEST, Marco Cantalamessa, Chief Marketing & CEO Staff Officer of SIMEST, who stressed the growing importance of ESG criteria in the evaluation of applications for financing a company’s development and growth activities; Maurizio Bellosta, Managing Director of Rubinetterie Bellosta and Vice-president of AVR, who explained how crucial is the approach to sustainability in a supplying company’s activity when considering to choose a supplier. Patrizia Ghiringhelli, Vice-president of UCIMU and Coordinator of the UCIMU Mark Committee.

The Sustainability Report refers to the year 2021 and was drawn up based on the replies to a questionnaire, which was sent to the associate member companies authorised to use the UCIMU Mark1. Among the 66 enterprises authorised to use the UCIMU Mark, 53 have replied. The evaluation questionnaire prepared by UCIMU in cooperation with ALTIS was created according to a materiality analysis, i.e. by focusing the attention on the sustainability areas that are more affected by the activity of the sector enterprises. In other words, the ESG areas subject to evaluation have been chosen considering 11 SDGs (Sustainable Development Goals) of the UN Agenda 2030, because they were more related with the business of machine tool enterprises.

Analysis Results
1 The Green-and-Blue-Action UCIMU Mark is granted to the associate member companies of UCIMU-SISTEMI PER PRODURRE that intend to operate while devoting the utmost attention to environmental, social and economic sustainability. In this sense, the UCIMU mark is an expression of the new business approach based on the new ESG principles (environmental, social and governance criteria), increasingly crucial also for those who operate in the manufacturing industry.

The results included in the Report are presented here below according to the three big areas, in which a company’s business is carried out in relation to the sustainability criteria (environmental, economic and social sustainability).

Environmental Sustainability
For the sector, the issue of circular economy (SDG 12 – Sustainable Consumption and Production) is an undisputed area of excellence, to such an extent that 62% of the interviewed enterprises have implemented good practises. Almost all the enterprises, 98%, carry out a differentiated waste collection; 76% have defined their own goals with regard to reduction of scraps and produced waste, whereas 50% use raw materials derived from recycling. From the point of view of carbon dioxide emissions (SDG 13- Climate Action), on the other hand, the enterprises of the sector must still configure their activity. Indeed, only 33% of the interviewed companies have defined goals related to the reduction of CO2 and, even less, 11% of them, have formalised these goals in an official document. Among the activities included in the package of good practises with regard to SDG 13, only 9% of the interviewed companies have considered the development of compensation actions, whose implementation costs would really be very reduced, taking into account the low environmental impact that the enterprises of this sector have by nature.

Social Sustainability
In a sector with high technological content and specialisation, where innovation is crucial for the competiveness of product offering, indeed, human resources and thus, high-quality education and training of co-workers (SDG 4 – Quality Education) are among the most important intangible assets. A percentage of 92% of the companies stated that they have set up or adopted a management system to meet the educational and training needs of their employees, whereas 87% have defined education & training goals for their co-workers. More than the half of these goals (54%) have been formalised. In addition, 63% of the companies stated that they offer education & training on cross-cutting competences, as well as on technical subjects and 82% stated that they have adopted procedures for the performance evaluation of their staff.

The enterprises also showed a strong commitment to the sustainable development of territory and community (SDG 11 – Sustainable Cities and Communities): a percentage of 68% of the enterprises proved to be conscious of their role as driving force of the growth, for example by providing economic contributions to support local bodies and young
talents.
Among the improvement areas, considering that of diversity and equal opportunities (SDG 5 – Gender Equality), it is necessary to work on the implementation of policies aimed at a higher inclusivity, both of female presences and young people, in a traditionally male sector. To date, the workforce is mainly male (86%). Young people represent a really small part compared with the total employees: 77% of the people who operate in the companies of the sector is aged over 30 years. Only 22% of the enterprises have a policy or a committee for the enhancement of diversity and the promotion of equal opportunities.

That said, among the good practises implemented by the companies with regard to equal opportunities and diversity, there is the implementation of a more inclusive policy, as well as the creation of company’s child day-care centres and actions to support maternity.

Finally, it is necessary for the enterprises to invest more in the governance of sustainability (SDG 16 – Peace, Justice and Strong Institutions) and in the formalisation of their own initiatives: indeed, only 30% of them inform about ESG issues through a dedicated section in their websites and only 4% have formalised this procedure by drawing up a reporting document, such as a Sustainability Report.

Economic Sustainability:
In the field of innovation (SDG 9 – Infrastructure and Industrialization), from digital transition to cybersecurity, enterprises are strongly involved in the development of innovative and effective technologies, capable of reducing the waste of resources, encouraging more sustainable consumption models and ensuring higher productivity for customer companies. Indeed, the results of the survey show that 91% of the enterprises have defined a strategy or future goals in terms of digitalisation, automation and industry 4.0.

Among the most common good practises, there is that concerning the development of digitalisation and communication projects with installed products, in order to enable a continuous monitoring, in agreement with customers, and predict maintenance needs. Actually, all this implies a reduction in production time and machine downtime, as well as an appropriate use of resources. These activities contribute to improving the competiveness of an enterprise.

With regard to Research & Development, 72% of the companies have defined a strategy or future goals aimed at a reduction in the environmental impact of products. Almost all the interviewed companies stated that they use labelling or education and training to inform their customers about the appropriate use of machines (91%) and about their correct disposal at the end of their lifecycle (72%).

Conclusions
Overall, the Sustainability Report 2021 shows a general lack of formalisation of processes: although 64% of the companies have defined strategies and goals, only 24% have formalised them. The percentage concerning the management and monitoring of sustainable paths, even if higher (39% in a formalised way), is still below 50%. On the other hand, the results of the Report highlight the need of the sector’s enterprises to strengthen their attitude to “disseminate sustainability” by implementing company’s practises ad hoc.

Companies can discover the potential for optimizing their production chain thanks to key performance indices, the famous KPIs. Among these indicators, the Overall Rate of Return contributes to give a complex and general measurement of the health of the factory or the production line. Indeed, thanks to the TRS the efficiency of the system is measurable, comparable and can therefore be optimized . Discover in this article everything there is to know about the TRS and how to improve it!

Synthetic Rate of Return: what is it?

The Synthetic Efficiency Rate, also called Overall Equipment Effectiveness, is an essential indication in the industry. This key indicator makes it possible to measure the production capacity of a manufacturing company or of a particular machine and also offers ways to increase its performance. This is an important indicator for maintaining control in production. Indeed, the TRS index highlights the level of waste of resources that should be corrected. It takes into account the most common and important sources of productivity loss in production, which means that production can be continuously improved. Improving OEE can therefore be used to increase the productivity of a workshop or factory.

How is the TRS calculated?

The Synthetic Yield Rate is calculated with the following formula: TRS = actual production/theoretical maximum production In the case of a machine in operation in a factory, the actual production will represent, for example, the number of valid parts produced over a period given. The theoretical maximum production will designate the total number of pieces produced during this period. In other words, the TRS measures the downtime of a machine and all its potential causes: breakdown, adjustments to be made. The TRS is expressed with a rate between 0% and 100%, the percentage of which is proportional to the quality. OEE is the product of the three fundamental components of production performance: Quality, Performance, Availability.

• Quality: the ratio between the number of viable parts produced and the total number of parts produced
• Performance: the ratio between the number of parts produced and the number of parts that could theoretically have been produced
• Availability: the ratio between the number of parts that could theoretically have been produced and the number of parts theoretically feasible

This rate thus makes it possible not only to calculate the extent of the losses, but also, depending on how it is calculated, to know their origin:

• Poor allocation of resources, human or financial for example
• Unexpected stops or slowdowns
• Operating anomalies: need for frequent repairs, poor organization of supplies, etc.

TRS: solutions to improve it
The higher the TRS, the lower the losses. The solution to improve the TRS of a machine is therefore to reduce its losses as much as possible to increase its efficiency. It is obviously necessary to start by calculating the TRS in detail, by noting, either automatically or manually, all the data necessary for its calculation. Once the data has been recorded, it is then necessary to visualize them as a whole to identify the source of the losses and downtime of the production unit, the main causes of a low OEE. Several solutions exist to improve your OEE, which must of course be chosen according to the sources identified. In general, OEE improvement solutions consist of improving the management of the production unit, whether in terms of management, maintenance, order tracking or inventory management.

Use TPM to get a higher OEE
Total Productive Maintenance (TPM), or total productive maintenance in French, is a Japanese method that includes various maintenance solutions. TPM aims to increase machine performance by offering a proactive approach to eliminating the six main causes of malfunction :

• Failures
• Settings and commissioning
• Waits, empty runs and micro-stops
• The loss of speed of the production line
• Startup failures
• Production defects and rejections

Identifying these sources of failure and eliminating them, allows a drastic reduction of unplanned downtime of the production line and consequently an improvement of the OEE.

Improving OEE using the SMED method
The Single Minute Exchange of Dies method, or rapid tool change in French, was developed with the aim of reducing the time for changeovers. This other Japanese method proposes to produce smaller batches to adapt more easily to changing customer demand. The SMED method thus makes it possible to reduce the changeover time necessary between two production periods , and therefore to reduce the downtime of the machines.

Opt for industry 4.0 to obtain a better OEE
With a market that is pushing for ever greater efficiency, the digital transition of companies is a medium-term imperative. Industry 4.0 relies on more connected machines and on automated data collection and archiving. Digitization of processes that makes OEE per machine easier to calculate . Micro-stops and breakdowns are detected and analyzed more precisely. In addition, thanks to data logging and traceability, the causes of these shutdowns are easily identified, in particular through the use of a digital twin to replay pre-failure scenarios.. It is precisely in order to improve the TRS that TopSolid’CamSimul includes a digital twin functionality, which makes it possible to reduce offline focusing. The automatic calculation of the TRS relieves the teams responsible for this task. Human interventions are kept to a minimum, reducing the risk of fraud and transcription errors. The TRS is generated automatically and can be consulted in real time by supervisors and analysts. World leader in CAD/CAM/ERP/PDM software publishing , TOPSOLID has created the Integrated Digital Factory. An integrated software suite for mechanical industries, building industries and digital engineering that marks TopSolid’s commitment to Industry 4.0. A 100% French product, TopSolid is the only solution that integrates both CAD/CAM and ERP. With a presence throughout France and a global network, choosing TopSolid is the guarantee of a close relationship coupled with nearly 40 years of expertise!

TOPSOLID is the world’s leading publisher of CAD CAM PDM software. With more than 40 years of experience under its belt, TOPSOLID is in a position to offer a fully integrated CAD CAM PDM solution. The company mainly targets the mechanical sector (machinery, tools, etc.), sheet metal work and the wood industry. Wherever a machine interacts with material to machine, shape or produce a part.

TOPSOLID India has introduced new initiatives to consolidate its footprint and provide more intensive support to its rapidly growing customer base in Maharashtra.

In pursuit of this objective, based on the increasing demand, TopSolid India shall commence direct customer support services from January 2023, particularly in Pune, Kolhapur, Satara, Sangli, Raigad, Solapur, Nashik, Aurangabad, Ahmednagar also neighbouring industrial cities in Belagavi & Goa.

Towards this end, TopSolid India’s endeavours shall be supported by: Mr. Sachinkumar Sawant responsible for heading the sales operations for the West zone. He has 16+ years of CAM products selling experience and has been inducted as Sales Head – Maharashtra & Goa.

Mr. Deepak Nalawade will be responsible for technical support. He has 17+ years of professional experience in the CAD/CAM industry and has been inducted as a Senior Application Specialist. This consolidation and expansion of services by TopSolid India shall contribute towards enhancing customer reach and improvement in service levels for TopSolid users, especially in the Maharashtra region.

At the close of the fiscal year 2021/22 on June 30, 2022, the TRUMPF Group recorded the highest sales revenues in the company’s 99-year history to date, with a strong increase in sales of 20.5 percent to 4.2 billion euros (fiscal 2020/21: 3.5 billion euros). The order intake increased by 42.1 percent to 5.6 billion euros (fiscal 2020/21: 3.9 billion euros). At 468 million euros, the Group’s operating earnings before interest and taxes (EBIT) grew positively by 26.8 percent compared to the previous fiscal year (370 million euros). TRUMPF was able to stabilize earnings through strong sales growth, particularly in the EUV business field, as well as by cutting non-personnel costs. As a result, TRUMPF achieved an EBIT margin of 11.1 percent (previous year: 10.5 percent).

Nicola Leibinger-Kammüller, CEO of TRUMPF: “Thanks to our systematic crisis management, TRUMPF has weathered the pandemic well, and has countered shortages in supply chains in the best possible way. As a result of the strong rise in demand in the second half of the year, we entered the new fiscal year with a high order intake. Nevertheless, there remains considerable uncertainty for the coming months as to how the supply chain bottlenecks, high inflation, rising material and energy prices and transportation costs will impact our business. Also making me pensive with regard to the overall economic trend are the geopolitical uncertainties; the war in Ukraine, for example, and also the tensions between the USA and China. We’re sensing growing restraint in demand in many markets.”

TRUMPF’s largest single markets

During the reporting period, the TRUMPF Group’s sales share shifted away from Asia in favor of Europe and North America: With sales revenues of 838 million euros in the fiscal year 2021/22 (previous year 461 million euros), the Netherlands is TRUMPF’s strongest single market in terms of sales for the first time. This increase corresponds to higher sales of 81.9 percent and is attributable to the strong growth of the EUV business segment with the client ASML. In addition, the USA has become the second strongest market with 656 million euros; in the previous fiscal year, the USA was still in third place. As a result, for the first time, Germany – with 589 million euros in sales revenues (previous year 579 million euros) – is no longer TRUMPF’s largest single market, but only ranks third. The largest Asian single market, China, lagged behind the strong growth of the previous year with an increase of just 9.6 percent to 575 million euros (previous year 525 million euros) and thus ranks fourth.

Corona infections and development of employee numbers until June 30, 2022

As of reporting date June 30, 2022, TRUMPF recorded 3,958 COVID infections globally (previous year: 877), 822 of which were in Ditzingen (previous year: 114). This is attributable to the overall greater number of infections abroad as well as advanced test diagnostics and systematic recording.

The number of TRUMPF employees increased by nearly 2,000 during the period under review. In particular, new jobs were created once again in the growth areas of EUV and Electronics. As of reporting date June 30, 2022, the company employed 16,554 people globally (previous year: 14,767). In Germany, the number of employees grew by 10.7 percent to 8,417 (previous year: 7,602). 4,894 of them work at the headquarters in Ditzingen and Gerlingen. In the year under review, 521 young people completed an apprenticeship or a co-op work-study program, resulting in a training ratio of 3.3 percent, which was slightly below the previous year (3.6 percent).

Effects of gas shortage and price increase / Climate protection

TRUMPF is not a gas-intensive company and primarily requires gas locally for heating its production and office buildings. The ratio of energy costs to sales revenues in the fiscal year 2021/22 was 1.0 percent (42 million euros/4,223 million euros). In the fiscal year 2022/23, however, the company is expecting a noticeable increase. In the past fiscal year, the TRUMPF Group’s natural gas consumption was 61,200 MWh. This corresponds to 3,600 4-person households. In Germany, consumption amounted to 35,600 MWh. This corresponds to 2,000 4-person households.

In the reporting period July 1, 2021 – June 30, 2022, the company was only marginally affected by the impact of the increase in gas prices due to a shortage of capacity. In April 2022, the TRUMPF Management Board nevertheless decided on anticipatory gas reduction measures in particular, which continue to the present day. From May 2022 onwards, over the summer months, gas consumption at the headquarters in Ditzingen could thus be reduced by a good half. The main measures included the use of new heat pumps, the reduction of system running times and dehumidification in the air-conditioning systems, especially in the offices, as well as system optimization measures (e.g. lowering setpoints). TRUMPF is currently examining further measures for the more heating-intensive winter months.

The TRUMPF Group’s electricity requirements globally amount to 166,000 MWh, of which Germany accounts for 100,400 MWh. The TRUMPF Group covers 100 percent of this demand with green electricity or was compensated by certificates.

Notwithstanding the discussions relating to energy consumption and supply, TRUMPF has implemented further climate protection measures in accordance with the company’s climate strategy. In addition to increasing energy efficiency at locations worldwide, thereby saving 1.5 percent electricity and 3 percent natural gas and heating oil annually, the focus is on increasing energy efficiency in the company’s own production by using process waste heat from production for heating. At the customer level, the company has driven measures to improve the environmental footprint of its products.

Investments and acquisitions

While investment was scaled back in the previous fiscal year due to the pandemic, it increased again in the fiscal year 2021/22. TRUMPF invested a total of 218 million euros (previous year: 145 million euros) in plots and buildings, technical facilities, and operating and office equipment.

In July 2021, TRUMPF increased its existing stake in the Dresden-based software company ZIGPOS GmbH from 25.1 percent to 51.3 percent. In August 2021, TRUMPF agreed on a strategic partnership with the Italian company STARMATIK S.r.l. and acquired a 25.1 percent stake in STARMATIK. The stake in SISMA S.p.A., also based in Italy, was increased from the previous 55.0 percent to 100.0 percent at the turn of the year 2021/22. At the beginning of 2022, TRUMPF acquired an 80.0 percent stake in Active Fiber Systems GmbH (AFS) in Jena for further development of the ultrashort pulse laser portfolio. In May 2022, we acquired the remaining 49.0 percent in the Indian software developer TRUMPF Metamation Private Limited.

TRUMPF is a research-intensive company, far above the industry average. The number of employees in research and development increased by 14.3 percent to 2,623 (previous year: 2,294). At 448 million euros, research and development expenditures were significantly higher than in the previous year (382 million euros). In relation to the sharp rise in sales revenues, the development ratio fell slightly to 10.6 percent (previous year: 10.9 percent), but still remained at a very high level well above the industry average.

Universal Robots extends its American partnership with Phillips Corporation to India, joining hands with the largest global distributor of best-selling Haas CNC machines for Indian manufacturers to boost productivity.Universal Robots extends its American partnership with Phillips Corporation to India, joining hands with the largest global distributor of best-selling Haas CNC machines for Indian manufacturers to boost productivity.

In an effort to boost productivity and help manufacturers emerge from the pandemic stronger than ever, pioneer and leading collaborative manufacturer Universal Robots (UR) joins hands with Phillips Machine Tools India, part of Phillips Corporation, the world’s largest Haas factory outlet. Together, they are all set to offer machine shops a safe, user-friendly solution to optimize uptime and enable significant advantages to manufacturers in India. This is an extension of the existing partnership between the two companies in the USA, which was first announced in August 2019.

Cobots are niche robotic arms which are quick to deploy, have a low footprint, and easy to program, even for those who are first time robot users. They overcome common barriers to automation faced by manufacturers in India, allowing them to implement Industry 4.0 technology. Traditionally, manufacturers face significant difficulties in the loading and unloading of CNC machines, which happens to be one the most popular applications of collaborative robots. Thus, the distributor agreement between Universal Robots India and Phillips Machine Tools India will ensure the rapid deployment of cobots with Haas CNC machines to help manufacturers staffing issues and stay competitive in this time of uncertainty. It will further offer affordable solutions to new and existing manufacturers and drive them to push the envelope by adopting flexible automation and increase overall productivity.

“Universal Robots India is pleased to partner with Phillips Machine Tools India, a Haas Factory Outlet, in bringing our solutions to the Automated Machine Tending marketplace in India. With Phillips’ extensive installed base and service network pan India, Universal Robots and Phillips India will bring the benefits of democratized & flexible automation to MSMEs, SMEs & OEMs as India emerges from the pandemic with a leaner but more productive & efficient manufacturing sector,” shares Pradeep David, General Manager, South Asia, Universal Robots.

Universal Robots has already sold over 44,000 cobots across the globe, with more than 1,000 UR cobots for tending Haas CNC machines. Phillips Corporation has an installed base of more than 19,000 Haas CNC machines around the world. More than 60 different Haas models can be automated with Universal Robots’ cobot arms. This partnership between the world’s largest distributor of the leading CNC brand and the top collaborative robot brand offers a slew of advantage for India’s manufacturers, combining a Haas-UR solution offered with Phillips’ CNC Manufacturing expertise and application know-how to help businesses boost productivity and also prepare for the possibility of any future disruptions.

“Today, more than ever before, it’s all about the competitive edge. We at PHILLIPS Machine Tools India offer innovative, affordable solutions that create an unbeatable competitive advantage for Indian manufacturing. PHILLIPS Automation through Universal Robots offers COBOTS: collaborative robots that provide cost-effective, flexible, and safe automation solutions for a wide range of CNC machine tending tasks. With over 10,000+ CNC machines and 10 technical centres spread across India we combine our machine tool expertise and automation experience to help our customers increase their machine productivity through simple, reliable automation, the PHILLIPS way,” says Terrence Miranda, Managing Director, Phillips Machine Tools India.

The companies see tremendous potential in both, retrofitting existing installations with UR cobots, and also for getting through the door to new customers, offering turn-key solutions. After all, there is no hardwiring or complex coding involved in getting a Universal Robot to communicate with a Haas machine since UR has solutions like the VersaBuilt software that facilitates two-way communication between the UR cobot and the CNC. This means UR cobots can easily execute any machining program stored on the Haas CNC directly through the cobot’s own teach pendant, maintaining all Haas safety interlock features. The partnership, thus, endeavors to take manufacturing in India to a whole new level, especially empowering those who are new to automation with a solution that enables Make in India with skyrocketed efficiency and quality.

Into its fifth year, ANCA’s industry-first competition launches for 2022 at the first ever GrindingHub – the new industry meeting place for grinding technology in Stuttgart, Germany. The ‘Oscars’ of the Cutting Tool industry, participants and winners achieve important brand recognition as well as cash and other prizes. Last year the awards achieved a total digital audience reach of 8.1 million readers via the media with 37 global entries seen by over 202,480 fans generating over 200,000​ engagement on social media.

Patrick Boland, Co-Founder at ANCA comments: “Every year brings yet another step change in technology that enables cutting tool makers to increase their sophistication in designing and manufacturing products. This year we bring our ANCA Integrated Manufacturing System (AIMS) to GrindingHub, a huge leap in technology to create the factory of the future. Efficient, automated and operating 24/7, the AIMS factory uses modular programs scripts, remote access, and cutting-edge machines to operate at maximum efficiency.”

“During my 40 plus years we consistently lead the industry designing advanced technology. For example in 1986 we launched the TG4 – the first machine ever to automate the measurement of tool geometry, thereby making regrinding possible. Reviewing Tool of the Year entries I am always in awe of the passion and talent of customers that push our machines to their limits and create tooling masterpieces.”

John Saunders, Saunders Machine Works and founder of YouTube channel NYC CNC

and first time Judge said: “Seeing the creative use of custom tooling is amazing.  Being able to reduce setups, improve cycle time, or even eliminate tools with the use of modern, custom carbide is something all shops should consider.  It’s an honor to be part of this competition and I hope it can help raise awareness about the benefits of a well-designed and executed cutting tool.”

ANCA Tool of the Year 2022
To find the Tool of the Year customers can submit their favourite tool with the winners being judged and announced live at IMTS. There will be two competition categories to recognise both the functionality and creativity of cutting tool manufacturers.

• The main prize goes to #MadeonANCA tools and entrants will be judged on the form and performance of their cutting tool.
• The second category is for virtual tools as the “Most innovative tool design”. Entrants are encouraged to be creative and use ANCA tool design software to push ideas to their limits.

The winner of #MadeonANCA receives $10,000 AUD worth of ANCA innovations for parts, accessories or software that fit your grinding needs or a trip to ANCA’s headquarters in Melbourne, Australia. This amazing prize comes with access as an ANCA VIP to exclusive opportunities with our ANCA experts. The winner of the most innovative virtual tool will receive the full CIM software package.

Submissions are open from 17th May to 8th August.

The competition will be based on the passion and the craft of tool making and celebrate our highly skilled tool grinding community. 

Judging panel

• Pat Boland, Co-Founder and Managing Director at ANCA
• John Saunders, Saunders Machine Works and founder of YouTube channel NYC CNC
• Thomson Mathew, Product Manager at ANCA
• Zoller – measure profile and diameter

At IMTS the top five finalist tools will be judged on the following criteria:

• Best surface finish in Ra (roughness average) value on the flute or gash surface
• The tool the that is closest to the nominal tolerance as stated on the drawing in terms of diameter and profile (i.e. if the tolerance on diameter is +/- 0.010mm and the tool is measured to 0.005 then this will rank favourably)
• Tool that has been ground to the tightest tolerance as per the drawing (i.e. the tool with the lowest tolerance will rank favourably)
• Level of complexity (i.e. in terms of the number of steps, profiles will rank favourably)