2010-ME01

PROJECT IN MECHANICAL ENGINEERING

INTEGRATION OF A TOOL PRE-SETTING AND

TOOL DELIVERY FOR TOOL SET-UP SYSTEMS

M.K. Abdul Rahim

Project Report 2010-ME01

Co-Worker: A.Z. Amzah

Supervisor: Dr. Martin McCarthy

Department of Mechanical Engineering

University of Auckland

21 September 2010

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INTEGRATION OF A TOOL PRE-SETTING AND TOOL

DELIVERY FOR TOOL SET-UP SYSTEMS

M.K. Abdul Rahim

ABSTRACT

This project focuses on the integration of a tool pre-setting and tool delivery for
tool set up system at Accord Precision. One of the major problems faced by the
company is to transfer tool offset data produced by the measuring device to the
Computer Numerical Control (CNC) machines efficiently. This is because the
current manual approach is evaluated as a bottleneck process; therefore, reduces
the efficiency of the production process. In conjunction with that, the main goal of
this project is to create an automated system to integrate the tool pre-setting and
tool delivery tasks.

An automated system requires an offset data to be transferred to the CNC

machines electronically. Data can be delivered to the CNC machines either by
using a flash drive or intranet system. Moreover, to upload the tool offset data to
the machines, a correct file format is required. Hence, Microsoft Excel is used to
convert the measured tool data into the offset file format required by the CNC
machine.

As a result, the automated system is more efficient when 12 or more tools are
used. It is estimated that 55% of time can be saved when measuring forty different
tools. Furthermore, the accuracy of a tool set-up and tool deliver processes can be
increased since the human mistakes and abnormalities from the manual approach
can be eliminated.

Thus, it was concluded that by implementing the automated system, the tool set-
up process will become more efficient, organized, systematic and accurate.

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Acknowledgement

First, I would like to thank my academic supervisor Dr. Martin McCarthy, lecturer in Mechanical
Engineering department for providing me with a lot of academic support and guidelines throughout the
project. Furthermore, I would like to express my gratitude to Accord‟s employees, especially Mr.
Russell Craft for allowing me carrying out the project the inside the company facility and giving me
advice regarding the technical aspects of the project. Last but not least I would like to express my
utmost appreciation to my project partner, Aqmal Zahran Amzah for his commitment and contribution
to this project. Thank you.

.................................................................
(MOHD KAMARULNIZAM ABDUL RAHIM)

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Table of Contents
Glossary of Terms and Abbreviations ................................................................................................ vi
1.0 Introduction ..................................................................................................................................... 1
1.1 Company Background ................................................................................................................... 1
1.2 Current Problem ............................................................................................................................ 1
1.3Terms and Definitions .................................................................................................................... 1
1.3.1 Tool Offset Values ................................................................................................................. 1
1.3.2 Tool Pre-Setting and Tool Delivery ....................................................................................... 2
1.4 Goal and Objectives ...................................................................................................................... 2
2.0 Current System Overview .............................................................................................................. 3
2.1 Plant Layout .................................................................................................................................. 3
3.0 Literature Review............................................................................................................................ 4
3.1 Measuring Device ......................................................................................................................... 4
3.2 Post Processor ............................................................................................................................... 4
3.3 CNC Milling Machines ................................................................................................................. 5
3.4 Data Delivery Modes .................................................................................................................... 5
4.0 Current System Time Cycle ........................................................................................................... 6
5.0 Data Transfer – Measuring Device to Computer ......................................................................... 6
6.0 Electronic Offset File - Formatting................................................................................................ 7
6.1 Post Processor ............................................................................................................................... 7
6.2 CNC Milling Machines ................................................................................................................. 7
6.3 Solutions........................................................................................................................................ 8
6.3.1 Alter Post Processor Codes .................................................................................................... 9
6.3.2 Acquire New Post Processor .................................................................................................. 9
6.3.3 File Conversion by Microsoft Excel ...................................................................................... 9
7.0 Electronic Offset File Converter by Microsoft Excel ................................................................. 10
7.1 Creating a Macro ......................................................................................................................... 12
7.2 Working Procedure ..................................................................................................................... 12
7.3 Outputs ........................................................................................................................................ 13
8.0 File Delivery Methods and Tool Pre-Setting............................................................................... 14
8.1 Flash Drive .................................................................................................................................. 14
8.2 Intranet system ............................................................................................................................ 14
8.2.1 CNC Machine Tool Pre-Setting ........................................................................................... 15
8.2.2 Computer Server Configuration ........................................................................................... 16
9.0 Automated System Trial ............................................................................................................... 17
9.1 Time Cycle Analysis ................................................................................................................... 17
9.2 System Compatibility Analysis ................................................................................................... 18
9.2.1 Outcomes.............................................................................................................................. 18
10.0 Results and Discussions .............................................................................................................. 19
10.1 Time Cycle Analysis ................................................................................................................. 19
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10.2 System Efficiency ..................................................................................................................... 19
10.3 System Compatibility ................................................................................................................ 20
10.3.1 Systems Comparison .......................................................................................................... 21
10.4 Automated System Overview.................................................................................................... 22
11.0 Conclusion .................................................................................................................................... 23
12.0 Challenges .................................................................................................................................... 23
13.0 Recommendations for Future Works ........................................................................................ 24
13.1 Remaining Issues ...................................................................................................................... 24
13.2 Recommendations for improvement ......................................................................................... 24
14.0 List of References ........................................................................................................................ 25
Appendix 1 – CNC Milling Machines ................................................................................................ 26
Appendix 2 – Manual Approach Time Study ................................................................................... 27
Appendix 3 – Data Transfer Connection .......................................................................................... 28
Appendix 4 – Excel Template Screenshots ....................................................................................... 31
Appendix 5 – Creating Macro ............................................................................................................ 33
Appendix 6 – Tool Offset File for CNC Machines ........................................................................... 35
Appendix 7 – CNC Machines Control Panel .................................................................................... 38
Appendix 8 – Automated System Time Study Sheet ........................................................................ 40
Appendix 9 – Excel Data Sheet for Five Tools.................................................................................. 44
Appendix 10 – Excel Data Sheet for Forty Tools and System Efficiency Data Sheet ................... 44

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Table of Contents
Figure 1: Accord Precision Ltd. .............................................................................................................. 1
Figure 2: Broken Tools. .......................................................................................................................... 2
Figure 3: Current System Overview........................................................................................................ 3
Figure 4: Plant Layout. ............................................................................................................................ 3
Figure 5: Measuring Device. ................................................................................................................... 4
Figure 6: CNC Machines......................................................................................................................... 5
Figure 7: Heidenhain Post Processor Output. ......................................................................................... 7
Figure 8: Maho Post Processor Output. .................................................................................................. 7
Figure 9: Mill Plus Post Processor Output. ............................................................................................. 7
Figure 10: Correct Offset File Format..................................................................................................... 8
Figure 11: Heidenhain Post Processor Codes.......................................................................................... 9
Figure 13: Machine 70 Offset File Template . ...................................................................................... 10
Figure 12: File Conversion by Microsoft Excel. ................................................................................... 10
Figure 14: Measured Values Template. ............................................................................................... 11
Figure 15: Output File Produced by the Excel Converter. .................................................................... 13
Figure 16: CNC Machine Tool Pre-Setting procedures. ....................................................................... 15
Figure 17: Computer Server Configuration Procedures. ....................................................................... 16
Figure 18: Time Cycle for Five Measured Tools. ................................................................................. 17
Figure 19: Time Cycle for Forty Measured Tools. ............................................................................... 19
Figure 20: Tool Number vs. Time Cycle. ............................................................................................. 20
Figure 21: Systems Comparison. .......................................................................................................... 21
Figure 22: Automated System Overview. ............................................................................................. 22

Glossary of Terms and Abbreviations

C++, JAVA, MATLAB = Programming languages

S drive = Electronic file storage network
G codes = Codes used to manufacture a product using CNC machine

CNC = Computer Numerical Control

DMG = Deckel Maho Gildemeister
GmbH = Gesellschart mit beschrankter Haftung
MC = Machine (CNC)
CAM = Computer Aided Manufacturing
DTE = Data Terminal Equipment
DCE = Data Circuit-Terminating Equipment
CD = Compact Drive
USB = Universal Serial Bus
DNC = Direct Numerical Control

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1.0 Introduction
In most manufacturing facilities, every CNC milling machine requires a set-up system of the
machining tools in order to allow the machine to identify the condition of the tools before
manufacturing process can begin. As a tool will be used in thousands of operation throughout its life
cycle, its condition and dimensions might change over time. The purpose of this project is to set up an
“automated system of tool pre-setting and tool delivery for the machining operation” at Accord
Precision Limited in Pakuranga, Auckland. This system to be developed to assist the operators of the
company to do their job more efficiently and systematically.

1.1 Company Background

Accord Precision Ltd, founded in 1980, is a privately
owned company with the majority of the shareholders
have been with the company since its inception. This
company employs seventy skilled employees and
operates in a 25000 m2 complex housing more than fifty
CNC lathe and CNC milling machines. Accord is New
Zealand largest „machined component manufactures‟
using rod, tube, slug, forging and casting forms [1]. On
top of that, this company also machine plastics from
rod, tube, moulding or piece form.
Figure 1: Accord Precision Ltd.
1.2 Current Problem
The most acute problem faced by the company is the bottleneck operations of tool pre-setting and tool
delivery for each CNC milling machine. A bottleneck is a process in an operation where the capacity
is less than demand placed upon that operation [2]. These current operations require operators to
measure the offset values of the tools and record those values manually by using pen and paper. Then,
they are required to input each of the values into the CNC machine‟s interface via a control panel.
Operators need first to record down the offset values, walk to the machine‟s control panel and key in
each value one by one. This bottleneck process also affects the production cost of the company
because it reduces productivity and the efficiency of the machining processes. It is estimated that
hundred thousand of dollars can be saved annually by reducing the time taken for this process.

1.3Terms and Definitions

1.3.1 Tool Offset Values
Every machining operation facility worldwide requires the initial setting-up of their CNC milling
machines by inputting the tool offset values into a machines‟ controller. These values are used by the
machine to interpret the condition of the tools in terms of their dimension and weariness. Tools need to
be measured and calibrated each time before the machining operation begins.

The tool offset values can be obtained by using a measuring device called DMG Micro vision 2. This
device measures the dimensions of the tools and compared them with the standard calibrated
dimensions to obtain the offset values. The details of the measuring device will be discussed later in
the report.

Furthermore, the absence of a tool offset values in CNC machines could be hazardous. This is because
the machines will assume that the conditions of the tools are perfect. As a result, it could damage the
tools and the machine‟s die. Consequently, the machining products are manufactured outside of their
specifications. Following figures are the examples of broken tool‟ images due to the absence of offset
values.

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Figure 2: Broken Tools.

1.3.2 Tool Pre-Setting and Tool Delivery

After all required offset values are obtained, an operator is required to deliver the tools and its offset
values to the CNC machine for a pre-setting process. This process requires the operator to place every
tool in the designated slot and key in the offset values using the control panel of the machine. Every
machine in the company has different version of control panel to aid the operators setting up various
activities, including setting up the tool offset values.

1.4 Goal and Objectives

The goal of this project is to create an automated system to integrate the tool pre-setting and tool
delivery processes. Automated system is defined as using the computer system and internal network to
integrate the processes hence eliminates the manual approach. In order to achieve this goal, a list of
objectives is established as followed:-

1) Reduce the time taken for the bottleneck processes

2) Eliminate the manual approach of writing down the offset values into a piece of paper
3) Eliminate the manual approach of manually inputting the offset values into the CNC
machine interface
4) Eliminate human errors while recording and inserting the tool offset values
5) Establish methods for tool offset delivery from the measuring device to the CNC
machine
6) Establish an approach to convert the measuring file of the offset values into a desirable file
format accepted by the CNC machine
7) Increase accuracy of tools delivery and tools pre-setup processes
8) Enhance safety of the working condition inside the facility

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2.0 Current System Overview

The diagram below illustrates the process flow of the current manual system.

START Select tools

required

Measure tools
Tool offset
values
Record tool offset
values

Key in values on End

CNC machine

Figure 3: Current System Overview.

Based on the diagram above, nearly four steps are required to complete the whole process. Firstly,
operators need to select the tools used for a particular product. Then, they need to measure the tools by
using a measuring device to obtain the offset values. Then, those values are recorded on a piece of
paper, and the operators will bring it to a particular CNC machine. At the machine, the tool offset
values are keyed in through a control panel and the tools are inserted into its designated slots.

2.1 Plant Layout

Diagram below illustrates the simplified plant layout in Accord facility including the location of CNC
machines, computer and measuring device.

Container MC67 3 MC 61 MC 58

MC 63 MC 70
2
MC 60 MC 59

Legends
MC 66 1 – Measuring Device
Other manufacturing 2 – Computer connected to
area measuring device
3 – Computer connected to
CNC machines
MC 59 - Control Panel
- Travelling route

Figure 4: Plant Layout.

** Both computers in the diagram are connected to the main server via intranet network system
** Note that measuring device and computer (2) are located inside the container
** Refer appendix 1 for full details on the CNC machines used for this project

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3.0 Literature Review

3.1 Measuring Device

The measuring device used in Accord is DMG Microset GmbH Microvision 2. This device was
manufactured by the DMG firm of Germany, and is widely available throughout the world. It has a
complete imaging system for automatic measuring of contours and measuring of tool cutting edges to
calculate relevant data [3]. The illustration of the measured object or tool is displayed on a bright, 10.4
inches screen together with the geometrical data, which is automatically calculated (refer appendix 1
for the measuring device details).

Connection to the external tool management system (computer) can be achieved by using Ethernet
interface or RS-232 port (see section 3.4). This connection will transfer the measured data from the
measuring device to the computer. In this case, computer will act as the controller for the measuring
device. Besides, Microvision 2 has a simple menu control system, operated with a regular mouse in
which all functions can be selected easily through the menu bar.

Figure 5: Measuring Device.

3.2 Post Processor

A post processor is a coded electronic file used to interpret the tool offset measurements by the
measuring device and convert the measurements into an electronic data that can be interpreted by the
CNC machine. This post processor is similar to the post processor used to translate data from CAM
system and transform it as a tape output file (G-Code) [4]. The only difference is the output it
produces. Furthermore, a post processor does not use any computer language such as Visual Basic,
C++ and MATLAB. It is an interpreter, which interprets the measuring device measurements
according to the instructions within the post file (post processor codes). The extension for a post
processor file is *.pp.

A post processor will create a new electronic output file or document of the measured tool offset
values, which can be uploaded and interpreted by the CNC machines. Note that different version of
CNC machine requires a different output format, thus requires a different version of post processor.
Usually the CNC machine manufacturer or the measuring device manufacturer will provide a suitable
post processor for a particular machine. Examples of the post processor available in Accord are
Heidenhain, Maho and Mill Plus.

Furthermore, post processor software is used for data transmission between a computer and a
measuring device. Although the post processors create a new electronic output file; it does not have
the function to transfer those file to the computer. Thus, software called TNCremont is used to obtain
the file created by the post processor. In order to obtain the file, computer and measuring device are
connected through the serial interface (RS-232) or the Ethernet interface. Moreover, the software
provides a convenient data transfer interface to establish a new output file created by the post
processor [5]. This software also can locate the newly converted output file into a desirable folder on

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the computer or into the main server storage. In addition, the output file can be viewed using a simple
Notepad or Word Pad program.

3.3 CNC Milling Machines

CNC milling machines inside Accord Precision facility are used to perform the machining processes
for the products based on the instructions given by the CAM system. The instructions given are
basically the guidelines on how to shape and produce a product from a block of raw materials [3]. The
same mechanism applies to the tool offset values operation. A measuring device will provide an
instruction for the CNC machine regarding the exact offset value of the tools. Consequently, it notifies
the machines the condition of the tools in terms of its dimension and weariness.

Figure 6: CNC Machines.

Most of the CNC machines have up to forty slots for tool placement (refer figure above). This means a
machine can be operated by using up to forty different tools in one time. This also means that one
machine can receive up to forty different offset values. Currently, operators will key in each offset
value to the machine via a control panel. Control panel for every machine is operated by a controller.
This controller will obtain those values and send the signal to the milling centre. Note that every
control panel has a different version of controller, thus can only interpret a specified format of the tool
offset file. Refer appendix 1 for a detailed list of the machines along with its properties.

For the purpose of this project, Accord requires nine machines inside the factory line to be integrated
with the new automated system. There are four different machine manufacturers which are HAAS,
Fanuc, Akira Seiki and Mynx. HAAS uses its own controller while others machine uses controller
designed by Fanuc. To summarise, HAAS machines can only receive an offset file format set by
HAAS and the same things is true for Fanuc machines [6] [7]. Further analysis of the controllers and
its suitable file format is discussed on section 6.2.

3.4 Data Delivery Modes

The machines at Accord vary from three to twenty years old. For the old machines, data delivery
modes are quite outdated, which uses the RS-232 interface and the floppy disk drive. RS-232 is a
standard for serial binary and control signals connecting between a DTE and a DCE [8]. It is
commonly used in computer serial port that connects a computer to an old printer. The port consists of
twenty five tiny holes to accommodate twenty five pins cable. Another mode is by using a floppy disk
drive to obtain the data from a floppy disk. For those who are not familiar with this mode, floppy disk
is a data storage medium that is composed of a disk of thin, floppy magnetic storage medium encased
in a square or rectangular shell [9]. This disk can store up to 200 megabytes of data depending on its
capacity. However, the usage of this mode has been superseded by the CD and flash drive.

As technology evolves, new modes have been introduced. Hence, many machine manufacturers begin
to use the flash drive or widely known as the USB drive for data delivery operation. This mode
requires a USB port on both machine and computer to accommodate the flash drive. The data delivery
operation using a flash drive is much quicker and easier. Besides, the drive is typically removable and
rewritable [10].

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Another mode for data delivery is by using Intranet system of the company. An intranet is a private
computer network that uses Internet Protocol technologies to share any part of an organization‟s
information [11]. This means all computers and machines inside the Accord facility are connected to
the main server which stores all information of the company. Nobody outside the company has access
to this network, and it is also protected by a security codes. Currently, Accord uses its intranet system
to transfer the G codes from a computer to the milling machines for the machining process. There are
few computers in the factory that have access to the server‟s information and can deliver the data
directly to the machine (refer section 2.1). Therefore, there might be a possibility to transfer the offset
values file using Intranet system.

4.0 Current System Time Cycle

Time cycle is the time required for the particular tasks to complete. For this project, time cycle is the
time taken starting from measuring the offset values using the measuring device until the values are
transferred to the CNC machine. This time cycle is very important to determine the efficiency of the
system. Therefore, this project will focus on the reduction of the time cycle. In order to achieve that,
time cycle for the manual approach is determined first. An experiment was carried out to obtain the
time cycle for the manual approach and it was found that on average 115.94 seconds are needed to
complete the process based on five try outs. In brief, an operator is required to spend nearly two
minutes to transfer the file to the CNC machines. Refer appendix 2 for the time study sheet used for
this experiment. Furthermore, in order to eliminate any abnormality during the experiment, an
experience operator is used to conduct the procedures. Hence, the average time cycle reflects the exact
time taken for the process.

5.0 Data Transfer – Measuring Device to Computer

In order to create an automated system, the measuring device must be connected to the computer. The
purpose of this connection is to transfer the electronic data file from measuring device to the
computer. As mentioned earlier, the post processor software, TNCremont will be used to obtain the
offset file and locate the file into a desirable folder on the computer. The format of the file depends on
the type of post processor used. In addition, Rs-232 cable is used to connect the measuring device with
the computer. Few experiments were being conducted to establish the connection and the result is
based on the following steps:-

1) Click on „System‟ tab on the measuring device monitor interface. Then click „PP-
measurement series‟ >>‟ New‟ >> „Heidenhain‟
2) Put tool in the slot and measure the offset by using the knob
3) Click „print‟ icon on the monitor
4) Key in tool number inside the blank space (beside T-NR). Then click „store‟
5) Repeat step 2 until step 4 to measure different tools
6) Open TNCremont software on the computer
7) Click on „server application‟ button
8) Open configuration window by clicking „configuration‟ button at the server window. At the
configuration window, select „MILL PLUS‟ as the control model and select „Receive (Data
I/O)‟ as the transfer protocol. Then click „OK‟
9) Create new file for the offset value by clicking „File‟ button. Then key in the file name and
choose the location of the file to be saved (for example c:/measuring outputs). Then click
„Save‟.
10) On the measuring device monitor, click Heidenhain icon
11) On the Heidenhain window, click „send list‟. List of offset values will be transferred to the
computer
12) Close the server window on the computer and open the offset file at the saved location

**This steps are accompanied by pictures to aid the users which can be referred at appendix 3.

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6.0 Electronic Offset File - Formatting

6.1 Post Processor

There are three different kinds of post processors available in the company. They are Heidenhain,
Maho and Mill Plus. In order to observe the format of the electronic file produced by these post
processors, every single post processor is tested using steps on section 5.0. From those steps, one can
see that the Heidenhain post processor is used to produce an output file (step 1). However, different
post processor can also be selected on „step 1‟ to produce a different format of output file. The figures
below illustrate the output format produced by the post processors:-

1) Offset file by using Heidenhain post processor

%BEGIN TOOL.T MM
T L R R2 DL DR PLC
1 L111.551 +0
%

Figure 7: Heidenhain Post Processor Output.

2) Offset file by using Maho post processor

%TM
T1 L111.551 ()
%
Figure 8: Maho Post Processor Output.

3) Offset file by using Mill Plus post processor

%TM
P1 T1 L111.551
%
Figure 9: Mill Plus Post Processor Output.
** The extension of these files are ‘*.txt*

From the output results, we can see that each post processor produces a different version of the offset
file. As mentioned earlier, the CNC machine can only accept the format of the output file determined
by its manufacturer. Hence, to prove this statement, these offset files were uploaded to the CNC
machine. Machine 70 was used to carry out this experiment. Unfortunately, the machine cannot
interpret any offset file produced by these post processors. Thus, it was assumed that these post
processors are not suitable for any CNC machine in the company.

6.2 CNC Milling Machines

Obtaining a precise offset file format is essential to ensure the milling machines understand the
instructions given by the measuring device. If the machines cannot understand those instructions, it
will assume there are no offset values for the tools. The consequence could be quite catastrophe. Thus,
there are two methods, which can be used to obtain a correct file format from the machines. One is by
using a flash drive and the other one is by using the intranet system in the company.

Using a flash drive is fairly easy. The first step is to insert the flash drive into the USB port on the
control panel. Then copy the tool offset values file to the flash drive by navigating the buttons on the
control panel. Most of the new HAAS milling machines has the USB port installed on its control
panel, and has the „copy‟ keypad on their control panel [6]. Example of HAAS machines which have
the USB compatibility are machine number 59, 66, and 70 (refer to appendix 1 for machine‟s
compatibility and refer section 8.2.1 for detailed steps on how to obtain offset file from the machines).

For the old machines or the machines which do not have USB compatibility, intranet network is used
to obtain the file. As mentioned in section 2.1, Accord has several computers connected to the main
server via intranet network. Data transfer between these two devices is accomplished using software
called Easy DNC. This software provides direct data transfer from computer to CNC machine using an
intranet network [12]. Usually, user is required to copy G-Codes file into the software, and the data

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will be automatically transferred to the machine (detailed steps on how to transfer or receive data is
explained in section 8.2.1). The advantage of this software is that it can communicate both ways. If
data can be uploaded to the machine, data also can be downloaded from the machine. Hence, to
acquire the correct offset file format from the machine, Easy DNC software has the function to do that.
To illustrate, figure below represents the example of a correct offset file format from the machine:-

%
(TOOL OFFSET)
N000 V13898
(DIMENSIONING= MM)
(LENGTH AND WEAR)
( CLNT_P L_GEOM L_WEAR R_GEOM R_WEAR FLUTES)
H01 C19 L0.000 W0.000 R0.000 E0.000 F2
H02 C17 L0.000 W0.000 R0.000 E0.000 F2
H03 C16 L0.000 W0.000 R0.000 E0.000 F2
H04 C17 L0.000 W0.000 R0.000 E0.000 F2
H05 C19 L0.000 W0.000 R0.000 E0.000 F2
H06 C19 L0.000 W0.000 R0.000 E0.000 F2
H07 C22 L0.000 W0.000 R0.000 E0.000 F2
H08 C19 L0.000 W0.000 R0.000 E0.000 F2
H09 C15 L0.000 W0.000 R0.000 E0.000 F2
......
......

Figure 10: Correct Offset File Format.

Note that the offset file shown above is for the Haas machine 70 only. The above illustration only
represents 15 % of the entire file. One file could contain up to 400 lines, which is not shown here. In
brief, figure above are the example of output file accepted by the machine for tool offset values. It was
also noticed that this format is different from the offset files produced by the post processors as shown
in section 6.1. One major problem arises from this difference is on how to convert the format produced
by the post processors into the format accepted by the machines. This will be discussed in the next
section.

6.3 Solutions
As mentioned in previous section, the main problem is how to transform measured tool offset values
file into a desirable format accepted by the CNC machines. The differences among the formats are due
to the incorrect post processors used. Thus, to solve this problem, post processors must be changed or
the codes within the post processors need to be altered. In conjunction with that, three approaches
were executed in order to produce a desirable format. Those approaches are:-

1) Alter the code of the post processor

2) Acquire new post processor from manufacturer
3) File Conversion using Microsoft Excel

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6.3.1 Alter Post Processor Codes
An experiment was conducted by altering few codes within the post processor file to find out whether
it can produce a similar desirable format. This is more of a trial and error approach. Few codes are
adjusted, omitted, added or replaced to see any adjustment made to the file. Example of codes used to
create a post processor is shown below.

[PARAMETER]
NAME="Heidenhain TNC-1"
UNIT="MM"
X="ABS"
X_DIA="NO"
Z="ABS"
Z_DIA="NO"
[TOOL_VALUE]
?Z?="%-9.3f"
?X?="%-9.3f"
[TOOL_INPUT]
?T-NR?="%2u"
[LIST]
?T-NR?
?Z?
[HEADER]
"BEGIN TOOL.T MM\r\n"
"T L R R2 DL DR PLC\r\n"
[TOOL]
"%-8u",?T-NR?
"%-+12.3f",?Z?
"+0",?X?
"\r\n"
[END]
Figure 11: Heidenhain Post Processor Codes.

The codes shown above are used inside the Heidenhain post processor. These codes produce an exact
offset file as illustrated on figure 10. Many alterations have been made to produce an output file
similar to the figure. However, none of these alterations produce the exact format. Furthermore, these
codes are not based on any familiar programming language such as C, C++ or JAVA. It is based on a
standard format approved by the machine‟s manufacturer and only people in that organization know
about the codes. As mentioned before, post processor is a translator, not common programming
software. Thus, it is almost impossible to learn this code in a restricted time scale and this experiment
is considered as unsuccessful.

6.3.2 Acquire New Post Processor

The second approach is to obtain the post processor externally. Many representatives related to this
project were contacted. Representatives from measuring device manufacturer such as DMG Mori
Seiki Australia and DMG America were contacted regarding on this matter. One representative from
DMG Australia responded and stated the price for each post processor. He explained that one post
processor could cost around 2100 Euros. This means more than 10000 Euros is needed to obtain all
required post processors. The cost of acquiring these post processors is enormous, and it is impractical
to buy a new post processor consisting of just few lines of code. After a discussion made with
Accord‟s representatives, this approach is omitted from this project. Thus, this approach is considered
as unsuccessful.

6.3.3 File Conversion by Microsoft Excel

File conversion is the last approach used in this project to produce a desirable format of the offset
values file. This conversion uses Microsoft Excel software as a medium to convert the file produced
by the measuring device. The following diagram illustrates this approach.

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File produced
by the Excel
measuring Accepted file
device Converter

Figure 12: File Conversion by Microsoft Excel.

Basically, after the electronic file of the tool offset values is transferred to the computer based on the
steps discussed in section 5.0, Microsoft Excel will convert the file and change the format of the file to
the acceptable format. Excel also will save the file automatically to the main server of the company or
to a flash drive. A special function called Macro inside the Excel software is used to assist this
approach. This function enables a user to record repetitive actions and then repeat the actions at the
click of a button [13]. Thus, users or operators do not have to worry about the conversion process or
the Macro functions inside Excel program. Detailed explanation regarding file conversion using
Microsoft Excel is explained in the next chapter.

7.0 Electronic Offset File Converter by Microsoft Excel

Excel converter is the solution chosen for this project to solve the formatting problem of the tool offset
file. This converter is capable on converting to any type of output format as long as the actual or
correct format is obtained first. As mentioned in section 6.2, data can be transmitted to and from the
CNC machines. Thus, a correct tool offset file was obtained from the machines. After acquiring the
correct file (refer section 8.2.1 for the working steps), the file was copied to Excel. Excel will treat the
file as a template during the conversion process which means the measured tool offset values will be
transferred into this template. Figure below shows the example of the CNC machine (machine 70)
offset file template in Excel converter.

Figure 13: Machine 70 Offset File Template [14].

Figure above represent the template required for machines 70. Note that this template is similar to the
desirable offset file as illustrated on figure 10. Moreover, as this project requires nine CNC machines
to be integrated, there will be nine different Excel converters for each machine. This is so since every
machine requires different offset formatting. Screen shot of every machine‟s template can be referred
at appendix 4.

Referred to the excel template above, there are two tabs on the program. One tab named „MC70‟ and
the other tab named „input‟. The function of the „input‟ tab is to list all measured tool offset values.
These values are obtained from the file produced by the measuring device (refer section 5.0). The
following figure illustrates this tab.

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Figure 14: Measured Values Template [14].

** ‘T’ represents tool number. ‘L’ represents tool offset values

Note that this template represents the output file produced by the measuring device using the
Heidenhain post processor. However, the format is slightly different in comparison to the output
format shown in figure 7 on section 6.1. This is because the codes inside the Heidehain post processor
are altered for this machine. As a consequence, due to the different format requirement for every
machine, there are three different types of post processors used for this project. Basically, these post
processors were being altered from the original Heidenhain post processor to be used by the measuring
device to produce an output file of the offset values. Then, the output file was transferred into Excel
converter for conversion purposes as shown in the diagram above. The newly altered codes of the post
processors and the outputs it produce are shown as followed.

[PARAMETER] [PARAMETER] [PARAMETER]

NAME="Haas" NAME="Haas MC 67" NAME="AkiraSeiki"
UNIT="MM" UNIT="MM" UNIT="MM"
X="ABS" X="ABS" X="ABS"
X_DIA="NO" X_DIA="NO" X_DIA="NO"
Z="ABS" Z="ABS" Z="ABS"
Z_DIA="NO" Z_DIA="NO" Z_DIA="NO"
[TOOL_VALUE] [TOOL_VALUE] [TOOL_VALUE]
?Z?="%-9.3f" ?Z?="%-9.3f" ?Z?="%-9.3f"
?X?="%-9.3f" ?X?="%-9.3f" ?X?="%-9.3f"
[TOOL_INPUT] [TOOL_INPUT] [TOOL_INPUT]
?T-NR?="%2u" ?T-NR?="%2u" ?T-NR?="%2u"
[LIST] [LIST] [LIST]
?T-NR? ?T-NR? ?T-NR?
?Z? ?Z? ?Z?
[HEADER] [HEADER] [HEADER]
"BEGIN TOOL.T MM\r\n" "BEGIN TOOL.T MM\r\n" "BEGIN TOOL.T MM\r\n"
"T L R\r\n" "T L R\r\n" "T L R\r\n"
[TOOL] [TOOL] [TOOL]
"%-8u",?T-NR? "%-8u",?T-NR? "%-8u",?T-NR?
"L%-+12.3f",?Z? "V%-12.3f",?Z? "%-12.3f",?Z?
//"R%-+12.3f",?X? //"R%-+12.3f",?X? //"R%-+12.3f",?X?
"\r\n" "\r\n" "\r\n"
[END] [END] [END]

%BEGIN TOOL.T MM %BEGIN TOOL.T MM %BEGIN TOOL.T MM

T L R T L R T L R
1 L88.580 +0 1 V88.580 +0 1 88.580 +0
3 L97.167 +0 3 V97.167 +0 3 97.167 +0
5 L188.994 +0 5 V188.994 +0 5 188.994 +0
8 L157.754 +0 8 V157.754 +0 8 157.754 +0
12 L168.744 +0 12 V168.744 +0 12 168.744 +0
For machine
24 L57.754 +0 67 24 V57.754 +0 24 97.754 +0
Figure 15: Post Processor and Figure 16: Post Processor and Figure 17: Post Processor and
Output File for Machine 59, 66, Output File for machine 67. Output File for Machine 60, 61,
70. 63, 68, 69.
The reason for using three different post processors is because some of the CNC machines require
special annotation for the offset values. For example, machine 67 requires a ‟V‟ letter before the
values and new HAAS machines (machine 70, 66, 59) require „L‟ letter before the offset values. On
the other hand, the remaining machines do not require any letter before the values.

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7.1 Creating a Macro

As mentioned in the earlier chapter, Macro function in Excel enables a user to records repetitive
actions and then repeats the actions at the click of a button. For this project, Macro functions are used
to obtain the measured offset file and to produce a new compatible offset file for the CNC machines.
The two buttons; „Import Measuring Data‟ and „Produce Output‟ as shown in figure 13 are the
examples of Macro function used (function of the buttons is describe on section 7.2). Furthermore,
Macro function can be found inside the „Developer‟ tab of Microsoft Excel. The following will
describe the steps to create a Macro for the Excel Converter:-

1) Imports CNC machine offset file (see section 6.2) into the Excel and locate it under the
„MC##‟ tab name. While importing, use the „Delimited‟ during the „import file wizard‟. Then
click next and choose „Tab‟ and „Space‟ as the delimiters
2) Click on the „Developer‟ tab.
3) On the CNC machine template, produce two separate buttons using „Insert‟ tab on the
„Controls‟ panel
4) Create Macros for both buttons by selecting the „Record Macro‟ function on the „Code‟ panel.
Note that each button used different macro
5) A „Record Macro‟ window will appear. Enters all details required for the Macro
6) After clicking the „OK‟ button, the Macro will start automatically. This means every work or
action performs in the Excel will be recorded. Also note the stop button on the bottom left of
the Excel window. This button needs to be clicked when the process are completed.
7) Import the measured offset values file into the Excel. Example of the file is shown in figure
14. Then, place the file in the „Input‟ tab section. After that click the „stop‟ button
8) Assign this Macro to the first button by right click on the button, and select „Assign Macro‟.
Assign Macro window will appear and then choose the required Macro name
9) Perform „Copy‟ and „Paste‟ action between the „Input‟ tab and the „MC##” tab in order to
transfer the offset values into the MC## tab. Below is the example of formula used to perform
this action
=IF(ISNA(VLOOKUP(1,[MC70.xlsm]Input!A2:B199,2,FALSE)),"L0.000",VLOOKUP(1,[MC70.xlsm]Input!A2:B199,2,FALSE))

10) Repeat step 5, 6, 7, and 8 to produce another Macro for „Produce Output‟ button. Lastly, save
the complete Excel Converter to the required folder for further operation
**Refer appendix 5 for work instruction of the steps above accompanied with aided pictures

The objective of using the Macros is to ease the data conversion process. User does not have to copy
and paste every single measured value to the CNC machine template. Hence the time taken to
complete this task will be reduced.

7.2 Working Procedure

As mentioned before, there are two buttons used for the Excel converter (refer figure 13). The
following steps will describe the usages of the buttons and explain the implementation of the Excel file
conversion approach:-

1) Transfer the tool offset values file to the computer using post processor software, TNCremont
2) Open an Excel converter of the respected machine (for example machine number 70)
3) Click on the „MC70‟ tab. Located at bottom left of the window
4) Click on the „Import Measuring Data‟ button. An „import text file‟ window will appear
5) Select the file produced by the measuring device („measuring device output.txt‟). The location
of the file is the same as when user saves the file using TNCremont (discussed in section 5.0)
6) Then click on the „Produce Output‟ button. The conversion process is done automatically
when the button is clicked. A desirable offset values output with a correct format will
automatically be saved to the main server or to the flash drive

After carrying out these steps, the converted offset file is obtained from the computer that connects to
the main server (and CNC machines) for file transfer process to the CNC machines. Alternatively, file
also can be saved into a flash drive. For this project, the Excel converter will automatically save the
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file either to the server or to a flash drive. At this stage, the tool offset values are ready for delivery
process.

7.3 Outputs
For this project, nine different Excel Converters are created for nine different CNC machine. Hence,
there will be nine different offset output produced by those converter. Example of output produced for
machine number 70 by the Excel converter is illustrated below.

%
(TOOL OFFSET)
N000 V13898
(DIMENSIONING= MM)
(LENGTH AND WEAR)
( CLNT_P L_GEOM L_WEAR R_GEOM R_WEAR FLUTES)
H01 C19 L88.580 W0.000 R0.000 E0.000 F2
H02 C17 L0.000 W0.000 R0.000 E0.000 F2
H03 C16 L97.167 W0.000 R0.000 E0.000 F2
H04 C17 L0.000 W0.000 R0.000 E0.000 F2
H05 C19 L188.994 W0.000 R0.000 E0.000 F2
H06 C19 L0.000 W0.000 R0.000 E0.000 F2
H07 C22 L0.000 W0.000 R0.000 E0.000 F2
H08 C19 L157.754 W0.000 R0.000 E0.000 F2
H09 C15 L0.000 W0.000 R0.000 E0.000 F2
H10 C16 L0.000 W0.000 R0.000 E0.000 F2
H11 C18 L0.000 W0.000 R0.000 E0.000 F2
H12 C18 L168.744 W0.000 R0.000 E0.000 F2
.....

Figure 15: Output File Produced by the Excel Converter.

The figure shown is not representing the whole document but with similar trends. It is also noticed that
the offset values are transferred based on its specified tool number. If there is no tool used for a
particular tool slot, zero values will represent the slot. Moreover, for different machine, the output file
is different. Refer appendix 6 for output examples of the remaining machines.

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8.0 File Delivery Methods and Tool Pre-Setting

Currently, the offset values taken from the measuring device will be delivered to the CNC machines
using a piece of paper containing all the values and tool numbers. An operator will bring that paper to
the specific CNC machine and type in those values by using a control panel. This approach could cost
a lot of time since the operator need to key in all those values individually. In conjunction with this
situation, an automated system is created to replace the manual approach. This means the file
containing the offset values will be transferred to the machine electronically which is more systematic
and less prone to human errors. There are two methods to deliver the file which are by using a flash
drive or by using the company's intranet system.

8.1 Flash Drive

In order to use this method, a CNC machine needs to have the USB port installed. Usually, only new
machine has this USB compatibility. Machines which have this feature in Accord are machine 59, 66,
and 70 (refer appendix 1 the machines‟ file delivery compatibility).These machines also have the same
version of the control panel and monitor interface. Hence, the procedures to deliver the file are
identical. Following are the steps for the file transfer:-

1) In the Excel Converter, press the „Produce Output‟ button. The data will be transferred
automatically into a flash drive. Also make sure that a flash is already connected to the USB
port before the button clicked
2) Bring the flash drive to the particular machine and insert the flash drive into a USB port
3) To set up the tool offset, Press the „list prog‟ button on the control panel
4) Select USB on the screen interface by navigating the arrows button on the control panel
5) Press „‟ key and then press „offset‟ key. The screen will show the previous offset interface
6) Type the name of the file including its extension. For example „MC60.prn‟
7) The press „F3‟ key to upload the file. The offset values will transferred to the CNC machine

**Refer appendix 7 for the images of the contol panel

8.2 Intranet system

This system will be applied on the old machines which do not have the USB port compatibility.
Basically, all machines other than machines stated in the previous section will be using this delivery
method. As explained before, sending data to the CNC machines using an intranet network system
requires software called EasyDNC to obtain the offset file from the main server storage system (s:\
drive) and send the file to the machines. For this project, EasyDNC is already installed to the computer
that connected to the CNC machines (refer section 2.1). Thus, an operator needs to go to that computer
after the data transfer process (refer section 5.0) to obtain the converted offset file from the main
server and then transfer the file to the machines. For simplicity, this computer is called „computer
server‟.

However, the CNC machines need to be in a „transfer mode‟ condition before the transfer process via
EasyDNC can take place. This is called tool pre-setting process. As a result, using an intranet system
as a delivery method comprises two phases, which are tool pre-setting and computer server
configuration.

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8.2.1 CNC Machine Tool Pre-Setting
As communication is done both ways between the computer server and CNC machine, an operator
need to set-up the CNC machine before data can be transferred from the computer server. Although
most of the machines are using Fanuc based controller, the version of the controllers are different
hence the control panel of the machines are also different. This means the set-up process for every
machine differs from one another. Table below describes the steps used to set-up the CNC machine
before the transfer process begins.

Machine Controller Steps

Press „RESET‟ key on the control panel
1)
68 and 69 Fanuc Oi-MB Turn the „Mode‟ knob into Edit position
2)
Press „Offset Setting‟ key to go to the tool offset values interface
3)
Select „Punch‟ tab based on the screen interface by navigating
4)
the buttons below the screen
5) Select „Exc‟ tab to execute transfer process
1) Press „RESET‟ key on the control panel
60 Fanuc O-MC 2) Press „READ WRITE‟ key
3) Press „/N.PAGE‟ and „3/SET‟ keys to go to the tool offset
values interface
4) Select „Punch‟ tab based on the screen interface by navigating
the buttons below the screen
5) Select „Exc‟ tab to execute transfer process
1) Press „RESET‟ key on the control panel
61 Fanuc O-M 2) Press „EDIT‟ key
3) Press „MENU OFFSET‟ key to go to the tool offset values
interface
4) Press „INPUT‟ key
1) Press „RESET” key on the control panel
63 Fanuc 21i-MB 2) Turn the „Mode‟ knob into Edit position
3) Press „Offset Setting‟ key to go to the tool offset values interface
4) Select „Punch‟ tab based on the screen interface by navigating
the buttons below the screen
5) Select „Exc‟ tab to execute transfer process
1) Press „RESET‟
67 HAAS 2) Press the „list prog‟ button on the control panel
3) Select USB on the screen interface by navigating the arrows
button on the control panel
4) Press „‟ key and then press „offset‟ key. The screen will show
the previous offset interface
5) Press „RECV RS-232‟ key
Receiving Data from the CNC Machines
All of the above CNC machines have the capability to transfer data to the computer server. This
function is really important in this project in order to obtain a correct offset file format from the
machine (see section 6.2). In order to send the data, the machine need to be in the „outputting data
mode‟ and instruction below must be followed.
1) For machine 60, 63, 68, and 69 – In step 4, select the „READ‟ tab instead of „PUNCH‟ tab
2) For machine 61 – In step 3, press „OUTPUT START‟ key instead of „INPUT‟ key
3) For machine 67 – In step 5, press „SEND RS-232‟ key instead of „RECV RS-232‟ key
Figure 16: CNC Machine Tool Pre-Setting procedures.

** Refer appendix 7 for the pictures of each control panel

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8.2.2 Computer Server Configuration
Computer server configuration is carried out by using computer server that connects to the CNC
machines (refer section 2.1). This computer is located in the middle of the CNC machines. Thus, it is
easy for the operator to navigate between the computer and CNC machines at one time. Presently, an
operator will use this computer to transfer G-Codes file to the machine. However, for this project, the
computer will be used to transfer the offset file to the machines. Furthermore, communication between
the computer and the machines is done both ways. This means the CNC machines need to be preset-up
first before the data can be transferred (see previous section). The table below explains the steps to
transfer offset file to the machines.

Steps Figure

1) Open the EasyDNC software

2) Select machine number
3) Click on the „Receive CNC
Data‟ tab (top right). Editor
window will appear

4) Click on the open tab

5) Select the offset file. For this
project the offset values file is
located at the S drive. The
address of the file is S:\Tool
Offset\MC##\MC##.txt

** Note that this file is the file

produced by the Excel Converter.
The converter will automatically
saved the file into the S drive

6) Click „Enqueue‟ table on the

editor window
7) Lastly, click „Send‟ on the
EasyDNC window

Receiving Data from CNC Machine

As pointed out before, computer server will be able to receive data from the CNC machine. This can
be done by setting up the control panel of the CNC machine into an „outputting data mode‟ (refer
previous section). On the EasyDNC, click on the „Receive CNC data‟ tab and leave the editor window
blank. This must be done before operator set-up the machine‟s control panel.
Figure 17: Computer Server Configuration Procedures.

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9.0 Automated System Trial

A full system trial was conducted on the new automated system to attain information in terms of its
performance, efficiency and reliability. Furthermore, this trial also will be used as a platform to
identify problems and malfunctions of the new system so that any minor problems can be fixed
immediately. In conjunction with that, the evaluations of the trial are divided into two categories,
which are the time cycle analysis and the system compatibility analysis. Evaluations on these
categories are essential to determine whether this project meets the objectives or not.

9.1 Time Cycle Analysis

In this analysis, time taken for implementing the new automated system on each machine is recorded.
Time cycle is a very important analysis for this project because it provides quantitative information on
the performance of the new system in comparison with the old system. Therefore, the time cycle for
each machine was taken starting from measuring the tools until uploading the offset values into the
CNC machines. Moreover, time cycle for automated system is separated into five categories, which
are measuring tools, transfer data to the computer, Excel conversion, travelling period and USB or
server configuration. The reason of splitting this time cycle is to analyse the contribution of each
category.

Experiments were carried out in Accord facility to record all the time cycles required. Data are
recorded on the time study sheet. Refer appendix 8 for the sample of time study sheet used for every
machine. Furthermore, all of these time cycles comprise the measurements of five different tools. This
means five offset values were measured and transferred to the machine. In a real situation, each
machine could contain up to forty different tools. Analysis on using a greater number of tools will be
discussed later in the report.

Diagram below illustrated the results of the experiment including time cycle taken for the manual
approach. Also refer appendix 9 for the Excel data sheet of this diagram.

Time Cycle for Five Tools

250

200

150
Time, s

Server/USB Config
100 Travelling
Excel Conversion
50
Transfer Data
Measuring Tools
0

Machine Number

Figure 18: Time Cycle for Five Measured Tools.

Note from the chart above, there are three categories comprising the time cycle for the manual
approach. The top category is the „key in offset values‟ (orange bar) which is not indicated on legend
section. Other than that, travelling time for the manual approach is taken as the total average from
travelling time of all machines.

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As results, based on the figure 18, it is clearly shown that the manual approach is much quicker in
comparison to the new automated system. Time taken for the manual approach is 115.94 seconds
whereas the fastest machine using the automated system took 119.4 seconds to complete (refer
appendix 9 for the data spreadsheet of the graph). It was also found that slower machines could take
up to 200 seconds to complete the automated system while faster machine could take up to 120
seconds. Furthermore, it is also noted that the time cycle time for machines using USB delivery
method (machine 59, 66, 70) is quicker compare to machines using an intranet system. Lastly, the
major difference between each machine time cycle occurs on the Server or USB configuration
category. This is mainly due to the age of the machines and the technology it employs. Some of the
older machine may use less efficient and less reliable technology thus could cause a slower server or
USB configuration process than the new machines.

In brief, manual approach is quicker than the automated system. An early assumption was made, and it
is because of the number of tools measured. If more tools are used, time taken on the measuring tools
and key in values categories will increase significantly for the manual approach. Thus, the time cycle
of the automated system could be shorter than the manual approach. Refer section 10.1 for further
discussion on this matter.

9.2 System Compatibility Analysis

In system compatibility analysis, the CNC machines compatibility with the new automated system is
analysed. This is done by transferring the converted tool offset file to the machines using a flash drive
or intranet system and check whether the CNC machines can accept the offset file or not. There are
few reasons why the machines cannot accept the file:-

1) The format of the converted offset file is different from the actual format (see section 6.2)
2) Insufficient amount of information in the offset file
3) The extension of the file is incorrect. For example, some machine required the file to be in
„*.prn‟ extension instead of „*.txt‟ extension.

For this project, offset file extension is standardized and will use „*.prn‟ extension only. This is
because all CNC machines in Accord can accept this file extension.

9.2.1 Outcomes
After the trial was conducted, it was found that every machine can accept the offset file transferred.
This means the CNC machines were successfully updated with the new values after the transfer
process is complete. Furthermore, every machine complies with its designated file delivery method,
either by using a flash drive or intranet system. However, there were some minor problems
encountered during the trial which is:-

1) An alarm signal appears on machine number 59, 66, and 70 after the transfer process is
completed. Nevertheless, the offset values still can be transferred successfully
2) Old offset values are being erased completely from the machines. This means the offset values
cannot being transferred in sequence
3) Wrong offset values are being transferred to the wrong machine. This usually happens when
using the intranet system delivery method where a user accidentally select the wrong machine
on the EasyDNC

All of these problems do not contradict with the objectives of this project. However, in order to
produce a perfect automated system, the problems need to be investigated and solved. Refer section
10.3 for further discussion on this matter.

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10.0 Results and Discussions

10.1 Time Cycle Analysis

Referring to the time analysis on section 9.1, it was found that the manual approach was consuming
less time in comparison to the automated approach. The main reason is because the trials were carried
out on five different tools. If more tools are used, it was assumed that the automated system will take
less time to complete than the manual approach. In conjunction with that, a projected bar chart using
forty different tools is produced to support this assumption.

In this bar chart, time in Measuring Tools category for every machine including the manual approach
is multiplied by eight. This is to forecast the time cycle for forty tools based on time cycle of five
tools. As more tools are used, time taken to measure the tools is also increased. Other than that, the
time in the Key-In Values category for the manual approach (orange bar) was also multiplied by eight
because it depending on the number of tools used. The greater number of tools used, the longer will be
the time taken to key in the offset values. For the automated system, time for Server/ USB
Configuration category remain the same despite of large number of tools used. This is because offset
data is transfer electronically. Below is the figure of the projected bar chart using forty different tools
(refer appendix 10 for the Excel data sheet).

Time Cycle for Forty Tools

900
800
700
600
Time, s

500 Server/USB Confiq

400
Travelling
300
200 Excel Conversion
100 Transfer Data
0 Measuring Tools

Machine Number

Figure 19: Time Cycle for Forty Measured Tools.

From the bar chart above, it was found that time cycle for the manual approach is significantly higher
compare to the automated system. This means the automated system is more efficient when many
tools are in used. It is also noted that the time gap between these two systems is really huge and at
least, 351.8 seconds of time cycle savings when using the automated system. This also meant at least
55% of time cycle can be saved on each machine if the automated system is implemented (based on
machine 68 and 69). As a result, it was proven that the new automated system is more efficient than
the manual approach if greater numbers of tools are used. The percentage of time that can be saved
also increases with the number of tools used. The key question is what would be the minimum number
of tools can be used in order for the automated system to be more time efficient? This will be
discussed in the next section.

10.2 System Efficiency

The efficiency of the automated system is based on the time cycle to complete the whole operations.
For the automated system to be efficient, its time cycle must be quicker than the time cycle of the
manual approach. As discussed in the previous section, the automated system will become more
efficient if large numbers of tools are used. To analyse this assumption, a projected line chart is
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produced. This chart will estimate the time cycle for a different number of tools on each system.
Moreover, this chart is constructed based on the data provided by previous bar charts, which can be
referred at appendix 9 and 10 for the Excel data sheet. Diagram below illustrates the line chart.

Tool Number vs Time Cycle

1000
900
800
700
600
Time, s

500
400 Manual
300
Automated
200
100
0 12
0 5 10 15 20 25 30 35 40 45 50
Tool Number

Figure 20: Tool Number vs. Time Cycle.

Beforehand, note that the time cycle on machine 68 and 69 are used to produce the line chart for the
automated system above. This is so since both machines have an identical and the uppermost time
cycle compared to other machines.

Based on the line chart, it was found that time cycles for both systems increase linearly with the
number of tools. Furthermore, the gradient line of the manual approach is much steeper compared to
the automated system. This means that as more tools are used, the cycle time for the manual approach
will increase rapidly. On the other hand, the gradient line for the automated system is much flatter.
Thus, increase in a number of tools will not vigorously affect the time cycle. Moreover, it was found
that both lines intersected when 12 tools are used. Hence, it is estimated that the automated system
will become more efficient if 12 or more tools are used.

Besides that, this line chart can be used as a benchmark chart. This means, Accord can use this chart to
estimate time cycle for a specific number of tools used on a particular system. They also can estimate
how much time can be saved if an automated system is being implemented. This information could be
very important for the company if they want to analyse cost-profit margin between these two systems.

10.3 System Compatibility

In this section, the compatibility of using an automated system for offset file integration with the CNC
machines is discussed. Based on the compatibility analysis on section 9.2, there are few problems
occurred during the trial. These problems are not critical but disrupt the performance of the system.
After a few experiments and discussion with Accord employees, there are considerable solutions,
which can be used to solve the problems. The solutions are:-

1) Alarm signals triggered from the machines can be turned off by using the „RESET‟ key on the
control panel. Every control panel has its own „RESET‟ key and operator only need to press
the key to set the alarm off. Pressing this key will not affect the tool offset file. Although the
alarm is triggered, the data still can be uploaded
2) When using the automated system, old offset values in the machine will be erased completely
and will be replaced by a new set of values. This means the converted offset values cannot be
transferred in sequence. The solution for this issue is to alert the operators that a set of tool
offset values must be transferred in „one go‟. Operators also must be aware that once offset
file is transferred to the machine, the old values will be erased

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 2010-ME01
3) The last concern is about transferring offset file to the wrong machine. As described earlier in
this report, every machine requires different version of offset file format. Thus, when an
operator accidentally transfers the file to the wrong machine, the machine will not accept the
file because the format is different

10.3.1 Systems Comparison

A comparison study was carried out between the new automated systems with the old manual
approach. The purpose of this study is to identify the strengths (advantages) and weaknesses
(disadvantages) of the new system in comparison with the old one. The table below illustrates the
study.

System Advantages Disadvantages

1) Automated. No pen and paper
Automated required. The whole system is based
on computers, USB drive, intranet
and CNC machines integration
2) More efficient when lots of tool are
used. This system will reduce the
time of the bottleneck process
3) Most systematic as the whole
system operates electronically.
Offset files can be stored in the
server storage system eternally
4) Information is protected securely
and data cannot be lost
5) Less prone to human errors
6) Easy to use. Operators is provided
with the step by step guidelines to
implement this system
7) Increase in competitive advantage of
the company because it employs an
up to date file transfer technology.
Also can increase the values of the
products
8) Information stored can be
transferred elsewhere when needed
with ease in no time, through the
intranet
1) More efficient if small number of
Manual tools are used
2) Less steps is required to complete
the system
3) There is no idle time in this system
4) No computer literacy required
Figure 21: Systems Comparison.
1) Less efficient when less than 12 tools
are used
2) Requires extra steps. Based on figure
18 automated system consists of five
main categories rather than three
categories from the manual approach
3) Server/USB category (figure 18)
consumes a lot of time. Operators
have to wait for this step to complete
while doing nothing – idle time
4) Could be very difficult to use for
people with low computer literacy
1) Less efficient if more than 12 tools
are used. Most of complicated
products require more than 12 tools
to manufacture
2) Not systematic. All of the offset data
is not stored into the database and
can be lost easily
3) Paper containing the offset values
could be mistakenly replaced by
values for other machine
4) A lot of times are required to key in
the offset values on the CNC
machine
5) Prone to human errors when
recording the measured values
6) Prone to human errors when typing
the values into the machines

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 2010-ME01

10.4 Automated System Overview

Select tools
START
required

Measure tools

Tool offset
values
Transfer tool offset
file into the
computer

Convert the file

using Excel
converter

Formatted Transfer the file to

Offset file the main server

Transfer the file to Configure server

No the flash drive software (EasyDNC)

Upload the file into Upload the file into

the CNC machine the CNC machine

File accepted by
the machine?

Yes

End

Figure 22: Automated System Overview.

Based on the diagram above, the initial steps for the automated system are quite similar to the old
system (refer section 2.1). However, for this system, the input of a tool offset values is transferred to
the computer. After that, the offset file is converted into its designated format using Excel Converter.
This converter will convert the measured offset file into a formatted file that can be accepted by the
CNC machine. Next, the file is delivered to the machine either by using an intranet system or flash
drive. For flash drive method, operator needs to bring the flash to the CNC machine and upload offset
file. On the other hand, if an operator is using the intranet system to transfer the file, an extra step is
required. After saving the converted offset file in the server storage system via intranet network,
operator needs to configure the computer server using software called EasyDNC. After the
configuration is done, the file can be transferred to the CNC machine via intranet network as well.

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 2010-ME01

11.0 Conclusion

Time Cycle and System Efficiency

It is concluded that by implementing the new automated system for tool delivery and tool pre-setup
processes, all of the proposed objectives are met. It was found that the efficiency of the automated
system increase linearly with the number of measured tools used. This means, the time cycle to
complete the process using the automated system is much faster if large numbers of tools are used. It
is estimated that 55% of time can be saved when using the automated system when measuring 40
tools.

Moreover, it was also found that the automated system will only become more efficient if more than
12 tools are used. This is one of the disadvantages of the automated system given that there will be a
process requires less than 12 tools. Since this disadvantage is due to the operating system of the
machines (in computer server and USB configuration), it is difficult to improve the efficiency.
However, it is recommended to use the automated system even though the efficiency is low.
Automated system has the advantages of preventing the human errors as well as making the tool set-up
process more systematic and accurate.

Significant Advantages
The automated system provides greater advantages in comparison to the manual approach. Besides
reducing time cycle, this new system eliminates any human errors caused by the operators since every
single file, and data will be transferred and delivered electronically using a computer and electronic
storage system. This means tool delivery and tool pre-setup processes will become more organize,
systematic and accurate. On another context, employing this new cutting edge technology will
increase the competitive advantage of the company.

Compatibility
The automated system is compatible with all CNC machines. This means offset file produced by the
Excel converter can be accepted by all CNC machines and the offset values can be transferred
effectively. Although there are some concerns occurred while conducting the file transfer process, it
can be solved or neglected as these concerns will not affect the overall outcomes of the project.

Overall Evaluation
In a nutshell, this project is considered as successful. The new automated system is recommended to
be used in Accord to fix the problems from the manual approach.

12.0 Challenges
There are few challenges encountered during this project that affects its progresses. It is important to
notice these challenges in order to perceive the limitations and constraints while conducting the
project. Following list describes those challenges:-

1) Availability of the CNC machines due to machines engaged for actual operation. This means
every experiment and test carried out on the machines must wait until the machines become
available and not under operation
2) Lack of expertise and knowledge in the development of the post processor. This is because the
post processor does not use any familiar programming language. It is an interpreter. Therefore,
it is quite difficult to understand the codes inside the post file
3) Old CNC machines‟ operating system is outdated and time-consuming thus, resulting in the
automated system becoming less efficient. The efficiency of the system can be increased if
machines integrated have the USB port compatibility
4) Short of time to extend the project to a greater depth. Overall outcome of the project can be
improved if enough time is provided to understand the codes of the post processor and the
operating system of the CNC machines

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 2010-ME01

13.0 Recommendations for Future Works

Even though all of the required objectives are met for this project, future works are necessary to
improve the outcomes in terms of the efficiency and reliability. Hence, more works are required on
particular areas such as:-

1) The practicality of the file converter

2) The efficiency of tool offset data transfer from the measuring device to the PC
3) The task of uploading the data into the CNC machine and increase the reliability of the new
automated system
4) Possible alternative methods besides Excel converter to produce tool offset data for the CNC
machines

13.1 Remaining Issues

Remaining issues are the faults and unexpected outcomes occurred while conducting this project.
These issues can be referred as:-

1) Inefficient working procedure to transfer data from the measuring device to the computer as
well as to convert the data into a correct format
2) Emergence of error message in some of the CNC machines after the offset data is uploaded

13.2 Recommendations for improvement

File Converter Recommendation

Combine nine separate Excel converters into a single program or file so that the file conversion
process for all of the CNC machines can be accessed from a single interface.

File Transfer Method Recommendations

1) Integrate the process of transferring the data from the measuring device to the computer with
the file conversion of Excel converter
2) Develop a single program that is able to handle both the file transfer from the measuring
device and the file conversion into the desired format

Error Message Recommendation

Investigate the solutions to stop alarm signals from triggering after the data is uploaded into the CNC
machine

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 2010-ME01

14.0 List of References

1 About Accord Precision. Retrieved June 24, 2010 from

http://www.accord.co.nz/index.php

2 Goldman, A. Resources For Entrepreneurs. Retrieved June 26, 2010 from

http://www.gaebler.com/Eliminating-Bottlenecks.htm

3 Kehde, J. Microvision 2. [User Manual] s.l. : DMG Microset Gmbh, 2004.

4 ICAM - Software Connecting CAD/CAM to CNC Machines. Retrieved June 26, 2010 from
http://www.icam.com/html/products/whatis/what_is_post.php

5 Heidenhain, J. TNCremont Help Guide. [Help Guide] s.l. : TNCremont.

6 Haas Automation Inc. [Operators Manual]. Haas. California : s.n., 2007. 96-8000.

7 Fanuc Ltd. Fanuc Series O-MC. [Operators Manual]. Japan : s.n., 1991.

8 Campbell, J. (1984) The RS-232 Solution. California : Sybex. 0-89588-140-3.

9 Watson, T. (2010) The Floppy Disk. Rogers Publishing Limited, May, 83, 17-17.

10 What is a Flash Drive? The Center for Technology and Professional Development.
Retrieved June 25, 2010 from
http://www.lakeland.cc.il.us/online/tutorials/flashdrive/print/flashdrive.pdf

11 Foreman, M. (1999) Save Trees, Build An Intranet. Index New Zealand, April, 17, 28-30.

12 EasyDNC. Retrieved June 27, 2010 from http://www.easydnc.com

13 Excel Macro Tutorial. Retrieved June 2010 from

http://www.helpwithpcs.com/tipsandtricks/microsoft-excel-macro-tutorial.htm

14 Amzah, A.Z. 2010 Integration of a Tool Pre-Setting and Tool Deliver for Tool Set up System, Part
IV project report, 2010-ME05.

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 2010-ME01

Appendix 1 – CNC Milling Machines

CNC Machines (Milling Department)

No Manufacturer Model Controller Year Data Transfer

59 HAAS Tm-2 unknown 2006 USB
60 Fanuc Robodrill T10C Fanuc O-MC 1996 Intranet
61 Fanuc Drillmate C-Model 10 Fanuc O-M 1991 Intranet
63 Mynx 540 Fanuc 21i-MB 2003 RS-232, Intranet
66 HAAS EC400 4AXSN unknown 2005 USB, Floppy disk
67 HAAS VF4 unknown 2000 Floppy disk, Intranet
68 Akira Seiki A-650 Fanuc Oi-MB 2005 Intranet
69 Akira Seiki A-650 Fanuc Oi-MB 2005 Intranet
70 HAAS VF4SS APC unknown 2007 USB, Intranet

Measuring Device

DMG Microset Gmbh ECO2 (2004)

V: 240 VA:200
Serial :99510001778

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Appendix 2 – Manual Approach Time Study

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Appendix 3 – Data Transfer Connection

Steps Figures
1) Click „System‟ tab on the measuring
device monitor interface. Then click
„PP-measurement series‟ >> New >>
Haas

2) Put tool in the slot and measure the

offset by using the knob

3) Click print icon on the monitor

4) Key in tool number inside the blank

space (beside T-NR). Then click „store‟

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 2010-ME01
5) Repeat step 2 until step 4 to measure
different tools
6) Open TNC Server window on the
computer
7) Click on server application button

8) Open configuration window by

clicking „configuration‟ button at the
server window. At the configuration
window, select „MILL PLUS‟ as the
control model and select „Receive
(Data I/O)‟ as the transfer protocol.
Then click „OK‟

9) Create new file for the offset value by

clicking „File‟ button. Then key in the
file name and choose the location of
the file to be saved. Then click „Save‟

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 2010-ME01
10) On the measuring device monitor, click
Haas icon

11) On the Haas window, click „send list‟.

List of offset values will be transferred
to the computer

12) Close the server window on the

computer and open the offset file at the
saved location

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Appendix 4 – Excel Template Screenshots

Machine 59 Machine 60

Machine 61 Machine 63

Machine 66 Machine 67

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Machine 68 Machine 69

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Appendix 5 – Creating Macro

Steps Figures

1) Imports CNC machine offset

file (see section 6.2) into the
Excel and locate it under the
„MC##‟ tab name. While
importing, use the „Delimited‟
during the „import file wizard‟.
Then click next and choose
„Tab‟ and „Space‟ as the
delimiters

2) Click „Developer‟ tab on the

Excel Menu bar
3) Produce two separate buttons
using „Insert‟ tab on the
„Controls‟ panel

4) Create Macros for both buttons

by selecting the „Record
Macro‟ function on the „Code‟
panel. Note that each button
used different macro

5) A „Record Macro‟ window

will appear. Enters all details
required for the Macro

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 2010-ME01

6) After clicking the „OK‟ button,

the Macro will start
automatically. This means
every work or action performs
in the Excel will be recorded.
Also note the stop button on
the bottom left of the Excel
window. This button needs to
be clicked when the process
are completed

7) Import the measured offset

values file into the Excel.
Example of the file is shown in
figure 15. Then, place the file
in the „Input‟ tab section. After
that click the „stop‟ button

8) Assign this Macro to the first

button by right click on the
button, and select „Assign
Macro‟. Assign Macro
window will appear and
choose the required Macro
name

9) Perform „Copy‟ and „Paste‟

action between the „Input‟ tab
and the „MC##” tab in order to
transfer the offset values into
the MC## tab. Use formula as
shown in the diagram

10) Repeat step 5, 6, 7, and 8 to

produce another Macro for
„Produce Output‟ button.
Lastly, save the Excel
Converter to the required
folder for further operation

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Appendix 6 – Tool Offset File for CNC Machines

Offset File for Machine 59 Offset File for Machine 60 Offset File for Machine 61
% % &HEFWOFF SET:% %
(TOOL OFFSET) G10 G90 P001 R 88.58 G10 G90 P001 R 88.58
N000 V-3623 G10 G90 P002 R 0 G10 G90 P002 R 0
(DIMENSIONING= MM) G10 G90 P003 R 97.167 G10 G90 P003 R 97.167
(LENGTH AND WEAR) G10 G90 P004 R 0 G10 G90 P004 R 0
( CLNT_P L_GEOM L_WEAR DIA_GEOD_WEAR G10 G90 P005 R 188.994 G10 G90 P005 R 188.994
FLUTES) G10 G90 P006 R 0 G10 G90 P006 R 0
H01 C00 L88.580W0.000 D0.000 E0.000 F2 G10 G90 P007 R 0 G10 G90 P007 R 0
H02 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P008 R 157.754 G10 G90 P008 R 157.754
H03 C00 L97.167W0.000 D0.000 E0.000 F2 G10 G90 P009 R 0 G10 G90 P009 R 0
H04 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P010 R 0 G10 G90 P010 R 0
H05 C00 L188.99W0.000 D0.000 E0.000 F2 G10 G90 P011 R 0 G10 G90 P011 R 0
H06 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P012 R 168.744 G10 G90 P012 R 168.744
H07 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P013 R 0 G10 G90 P013 R 0
H08 C00 L157.75W0.000 D0.000 E0.000 F2 G10 G90 P014 R 0 G10 G90 P014 R 0
H09 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P015 R 0 G10 G90 P015 R 0
H10 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P016 R 0 G10 G90 P016 R 0
H11 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P017 R 0 G10 G90 P017 R 0
H12 C00 L168.74W0.000 D0.000 E0.000 F2 G10 G90 P018 R 0 G10 G90 P018 R 0
H13 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P019 R 0 G10 G90 P019 R 0
H14 C00 L0.000 W0.000 D0.000 E0.000 F2 G10 G90 P020 R 0 G10 G90 P020 R 0
....... G10 G90 P021 R 0 G10 G90 P021 R 0
....... G10 G90 P022 R 0 G10 G90 P022 R 0
G154 P91 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P023 R 0 G10 G90 P023 R 0
G154 P92 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P024 R 57.754 G10 G90 P024 R 57.754
G154 P93 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P025 R 0 G10 G90 P025 R 0
G154 P94 X0.000 Y0.000 Z0.000 A0.000 B0.000 ..... G10 G90 P026 R 0
G154 P95 X0.000 Y0.000 Z0.000 A0.000 B0.000 ...... G10 G90 P027 R 0
G154 P96 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P192 R 0 G10 G90 P028 R 0
G154 P97 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P193 R 0 G10 G90 P029 R 0
G154 P98 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P194 R 0 G10 G90 P030 R 0
G154 P99 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P195 R 0 G10 G90 P031 R 0
G92 X0.000 Y0.000 Z0.000 A0.000 B0.000 G10 G90 P196 R 0 G10 G90 P032 R 0
% G10 G90 P197 R 0 %
G10 G90 P198 R 0
G10 G90 P199 R 0
G10 G90 P200 R 0
%

35
 2010-ME01
Offset File for Machine 63 Offset File for Machine 66 Offset File for Machine 67
% % %
G10 G90 L11 P001 R 0 (TOOL OFFSET) (TOOL OFFSET)
G10 G90 L13 P001 R 0 N000 V13898 N0000 V38512
G10 G90 L10 P001 R 88.58 (DIMENSIONING= MM) N0001 V88580
G10 G90 L12 P001 R 0 (LENGTH AND WEAR) N0002 V0
G10 G90 L11 P002 R 0 ( CLNT_P L_GEOM L_WEAR DIA_GEOM D_WEAR N0003 V97167
G10 G90 L13 P002 R 0 FLUTES) N0004 V0
G10 G90 L10 P002 R 0 H01 C19 L88.580 W0.000 D0.000 E0.000 F2 N0005 V188994
G10 G90 L12 P002 R 0 H02 C17 L0.000 W0.000 D0.000 E0.000 F2 N0006 V0
G10 G90 L11 P003 R 0 H03 C16 L97.167 W0.000 D0.000 E0.000 F2 N0007 V0
G10 G90 L13 P003 R 0 H04 C17 L0.000 W0.000 D0.000 E0.000 F2 N0008 V157754
G10 G90 L10 P003 R 97.167 H05 C19 L188.994 W0.000 D0.000 E0.000 F2 N0009 V0
G10 G90 L12 P003 R 0 H06 C19 L0.000 W0.000 D0.000 E0.000 F2 N0010 V0
G10 G90 L11 P004 R 0 H07 C22 L0.000 W0.000 D0.000 E0.000 F2 N0011 V0
G10 G90 L13 P004 R 0 H08 C19 L157.754 W0.000 D0.000 E0.000 F2 N0012 V168744
G10 G90 L10 P004 R 0 H09 C15 L0.000 W0.000 D0.000 E0.000 F2 N0013 V0
G10 G90 L12 P004 R 0 H10 C16 L0.000 W0.000 D0.000 E0.000 F2 N0014 V0
G10 G90 L11 P005 R 0 H11 C18 L0.000 W0.000 D0.000 E0.000 F2 N0015 V0
G10 G90 L13 P005 R 0 H12 C18 L168.744 W0.000 D0.000 E0.000 F2 N0016 V0
G10 G90 L10 P005 R 188.994 H13 C16 L0.000 W0.000 D0.000 E0.000 F2 N0017 V0
G10 G90 L12 P005 R 0 H14 C21 L0.000 W0.000 D0.000 E0.000 F2 N0018 V0
G10 G90 L11 P006 R 0 H15 C22 L0.000 W0.000 D0.000 E0.000 F2 N0019 V0
G10 G90 L13 P006 R 0 H16 C17 L0.000 W0.000 D0.000 E0.000 F2 N0020 V0
G10 G90 L10 P006 R 0 H17 C19 L0.000 W0.000 D0.000 E0.000 F2 N0021 V0
G10 G90 L12 P006 R 0 H18 C19 L0.000 W0.000 D0.000 E0.000 F2 N0022 V0
G10 G90 L11 P007 R 0 H19 C00 L0.000 W0.000 D0.000 E0.000 F2 N0023 V0
G10 G90 L13 P007 R 0 H20 C00 L0.000 W0.000 D0.000 E0.000 F2 N0024 V57754
G10 G90 L10 P007 R 0 H21 C24 L0.000 W0.000 D0.000 E0.000 F2 N0025 V0
G10 G90 L12 P007 R 0 H22 C27 L0.000 W0.000 D0.000 E0.000 F2 N0026 V0
G10 G90 L11 P008 R 0 H23 C20 L0.000 W0.000 D0.000 E0.000 F2 N0027 V0
G10 G90 L13 P008 R 0 H24 C21 L57.754 W0.000 D0.000 E0.000 F2 .....
G10 G90 L10 P008 R 157.754 H25 C00 L0.000 W0.000 D0.000 E0.000 F2 .....
G10 G90 L12 P008 R 0 H26 C16 L0.000 W0.000 D0.000 E0.000 F2 N1176 V32
G10 G90 L11 P009 R 0 ..... N1177 V32
...... ..... N1178 V32
...... T34 P9 L32 N1179 V32
G10 G90 L10 P063 R 0 T35 P28 L32 N1180 V32
G10 G90 L12 P063 R 0 T36 P26 L32 N1181 V32
G10 G90 L11 P064 R 0 T37 P14 L32 N1182 V32
G10 G90 L13 P064 R 0 T38 P3 L32 N1183 V32
G10 G90 L10 P064 R 0 T39 P39 L32 N1184 V32
G10 G90 L12 P064 R 0 T40 P32 L32 N1185 V32
% T41 P2 L32 %
%

36
 2010-ME01

Offset File for Machine 68 Offset File for Machine 69 Offset File for Machine 70
% &H E:&FWOFF SET:% % &H E:& FWOFF SET :% %
G10 G90 L11 P001 R 0 G10 G90 L11 P001 R 0 (TOOL OFFSET)
G10 G90 L13 P001 R 0 G10 G90 L13 P001 R 0 N000 V13898
G10 G90 L10 P001 R 177.053 G10 G90 L10 P001 R 88.58 (DIMENSIONING= MM)
G10 G90 L12 P001 R 0 G10 G90 L12 P001 R 0 (LENGTH AND WEAR)
G10 G90 L11 P002 R 0 G10 G90 L11 P002 R 0 ( CLNT_P L_GEOM L_WEAR R_GEOM R_WEAR FLUTES)
G10 G90 L13 P002 R 0 G10 G90 L13 P002 R 0 H01 C19 L88.580 W0.000 R0.000 E0.000 F2
G10 G90 L10 P002 R 188.525 G10 G90 L10 P002 R 0 H02 C17 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L12 P002 R 0 G10 G90 L12 P002 R 0 H03 C16 L97.167 W0.000 R0.000 E0.000 F2
G10 G90 L11 P003 R 0 G10 G90 L11 P003 R 0 H04 C17 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L13 P003 R 0 G10 G90 L13 P003 R 0 H05 C19 L188.994 W0.000 R0.000 E0.000 F2
G10 G90 L10 P003 R 200.113 G10 G90 L10 P003 R 97.167 H06 C19 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L12 P003 R 0 G10 G90 L12 P003 R 0 H07 C22 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L11 P004 R 0 G10 G90 L11 P004 R 0 H08 C19 L157.754 W0.000 R0.000 E0.000 F2
G10 G90 L13 P004 R 0 G10 G90 L13 P004 R 0 H09 C15 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L10 P004 R 200.094 G10 G90 L10 P004 R 0 H10 C16 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L12 P004 R 0 G10 G90 L12 P004 R 0 H11 C18 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L11 P005 R 0 G10 G90 L11 P005 R 0 H12 C18 L168.744 W0.000 R0.000 E0.000 F2
G10 G90 L13 P005 R 0 G10 G90 L13 P005 R 0 H13 C16 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L10 P005 R 224.027 G10 G90 L10 P005 R 188.994 H14 C21 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L12 P005 R 0 G10 G90 L12 P005 R 0 H15 C22 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L11 P006 R 0 G10 G90 L11 P006 R 0 H16 C17 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L13 P006 R 0 G10 G90 L13 P006 R 0 H17 C19 L0.000 W0.000 R0.000 E0.000 F2
...... G10 G90 L10 P006 R 0 H18 C19 L0.000 W0.000 R0.000 E0.000 F2
...... G10 G90 L12 P006 R 0 H19 C00 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L11 P398 R 0 G10 G90 L11 P007 R 0 H20 C00 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L13 P398 R 0 G10 G90 L13 P007 R 0 H21 C24 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L10 P398 R 0 G10 G90 L10 P007 R 0 H22 C27 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L12 P398 R 0 G10 G90 L12 P007 R 0 H23 C20 L0.000 W0.000 R0.000 E0.000 F2
G10 G90 L11 P399 R 0 G10 G90 L11 P008 R 0 .......
G10 G90 L13 P399 R 0 G10 G90 L13 P008 R 0 .......
G10 G90 L10 P399 R 0 G10 G90 L10 P008 R 157.754 T33 P19 L32
G10 G90 L12 P399 R 0 G10 G90 L12 P008 R 0 T34 P25 L32
G10 G90 L11 P400 R 0 G10 G90 L11 P009 R 0 T35 P41 L32
G10 G90 L13 P400 R 0 G10 G90 L13 P009 R 0 T36 P24 L32
G10 G90 L10 P400 R 0 ...... T37 P29 L32
G10 G90 L12 P400 R 0 ...... T38 P23 L32
% G10 G90 L11 P399 R 0 T39 P28 L32
G10 G90 L13 P399 R 0 T40 P36 L32
G10 G90 L10 P399 R 0 T41 P4 L32
G10 G90 L12 P399 R 0 %
G10 G90 L11 P400 R 0
G10 G90 L13 P400 R 0
G10 G90 L10 P400 R 0
G10 G90 L12 P400 R 0
%

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Appendix 7 – CNC Machines Control Panel

Machine 59 Machine 66

Machine 67 Machine 70

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Machine 60 Machine 61

Machine 68 & 69 Machine 63

39
 2010-ME01

Appendix 8 – Automated System Time Study Sheet

Machine 70

Machine 68 & 69

40
 2010-ME01

Machine 61

Machine 67

41
 2010-ME01

Machine 63

Machine 59

42
 2010-ME01

Machine 60

Machine 66

43
 2010-ME01

Appendix 9 – Excel Data Sheet for Five Tools

Measuring Transfer Total

Machine Tools Data Excel Travelling Server/USB Time (s)
59 32.15 25.86 26.05 20.95 16.38 121.39
66 32.15 25.86 26.05 19.04 16.04 119.14
70 32.15 25.86 26.05 17.57 20.56 122.19
60 32.15 25.86 26.05 22.58 30.57 137.21
61 32.15 25.86 26.05 24.79 24.37 133.22
63 32.15 25.86 26.05 15.28 34.93 134.27
67 32.15 25.86 26.05 18.41 78.55 181.02
68 32.15 25.86 26.05 24.87 95.3 204.23
69 32.15 25.86 26.05 24.87 95.3 204.23
Manual 48.82 20.92 46.2 115.94

Appendix 10 – Excel Data Sheet for Forty Tools and System Efficiency
Data Sheet

Measuring Transfer Total

Machine Tools Data Excel Travelling Server/USB Time (s)
59 257.2 25.86 26.05 20.95 16.38 346.44
66 257.2 25.86 26.05 19.04 16.04 344.19
70 257.2 25.86 26.05 17.57 20.56 347.24
60 257.2 25.86 26.05 22.58 30.57 362.26
61 257.2 25.86 26.05 24.79 24.37 358.27
63 257.2 25.86 26.05 15.28 34.93 359.32
67 257.2 25.86 26.05 18.41 78.55 406.07
68 257.2 25.86 26.05 24.87 95.3 429.28
69 257.2 25.86 26.05 24.87 95.3 429.28
Manual 390.56 20.92 369.6 781.08

Data Sheet for Systems Efficiency

Tools Manual (s) Automated (s)

5 115.94 204.23
10
15
20 401 300.68
25
30
35
40 781.08 429.28

** Values for blank columns are projected using the line graph

44