May 2025 Volume 7

AUTOMATION

AUTOMATION AND TOOL MANAGEMENT Driving Efficiency in the Tooling Industry By Bailey Taylor

I n today’s competitive manufacturing environment, automation is often thought of as something reserved for large-scale forging or production facilities. However, automation and data-driven processes are just as critical — and perhaps even more impactful — in the supporting industries that supply

At the core of the project is the ZOLLER TMS (Tool Management Software). This system provides a digital backbone for our entire tooling operation — tracking tool locations, recording life cycle data, and integrating with the rest of our equipment to automate many of the manual processes that previously consumed valuable production time. As Brooks Hay, Regional Sales Manager at ZOLLER Inc., explains: "ZOLLER Solutions provides the ability to track and manage tooling from art to part. With the ZOLLER Tool Management Solutions (TMS) software, users can define and create the digital twin of their single components and tool assemblies. Using the ZOLLER interfaces to CAD/CAM systems, programmers are now able to access these digital twins from the ZOLLER TMS library. This standardizes the selection of tools from one single source database, ensuring that the programming is done with tools that are on the shop floor. Once programs are created and setup sheets are made, operators are guided through the TMS software exhibiting where each component is located. When using ZOLLER TMS vending solutions, such as the ZOLLER »toolOrganizer« (ZTO) and the vertical »keeper« cabinet for holders and assemblies, inventories are managed through a secure electronic locking system. Access to these components and tool assemblies is achieved through checking in/checking out using the TMS software, giving live visibility to component locations, inventory quantities, and operator activity. During the checkout process, the ZTO and »keeper« provide a guide light indicating which drawer or single compartment is unlocked. This ensures the correct items are selected, preventing the ability to access other stored pieces.

forged tooling and precision machined components. At EST Tool & Machine, Inc., we are currently undertaking a forward-thinking project aimed at transforming our internal tooling management

system. While our facility is not a forging operation itself, we serve the forging industry daily — and this project is a testament to how modern automation and storage principles can deliver substantial benefits even in a precision job shop environment. The Challenge: Managing Complex Tooling in a Custom Environment Forging tooling presents unique challenges. No two jobs are exactly alike. Some tools are used daily, while others may only see service once a year. In a busy CNC and tooling environment, this creates logistical headaches: Where is that tool we only use twice a year? Has it been scrapped, lost, or mistakenly used in another setup? Is the tool we’re pulling for a job brand new — or is it already near the end of its life cycle? At EST Tool, we recognized that traditional tooling cribs and manual tracking methods were no longer sufficient to support the level of service and quality our customers expect. This led us to embark on an ambitious tooling crib automation project designed to solve these problems while increasing efficiency and reducing overall costs. The Solution: Integrated Tool Management & Automation Technology Our current project centers around a fully integrated tool management ecosystem powered by ZOLLER’s industry-leading technology, coupled with new equipment investments to support permanent tool marking and tracking.

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