May 2025 Volume 7

AUTOMATION

As tool assemblies are properly made, they are taken to the ZOLLER presetter where they are measured. By eliminating the spindle downtime of touching off in the machine, the offline ZOLLER presetter proactively and accurately measures the tool parameters down to the micron. This ensures the tool lengths, diameters and other tool geometries are to specifications and captures the measured tool offset data. Located at each machine, the ZOLLER »zidCode« automates the data transfer of the tool offsets into the machine control with the simple scan of a QR code assigned to that tool assembly. This eliminates any worry of incorrect data entry. These ZOLLER Solutions cohesively work together providing a big picture solution to companies wanting to standardize and manage tooling, increase visibility and efficiency, reduce scrap and waste. This results in an optimized and efficient production process." To complement the TMS software, we are outfitting our facility with ZOLLER Organizer Cabinets. These storage systems are more than just shelves — they are smart storage solutions that communicate directly with our software. When a tool, cutter, insert, or even a fastener is removed from storage, the system logs that action automatically. This eliminates guesswork, prevents shortages, and ensures that every tool can be located when it’s needed most. In addition to storage and tracking, we are also implementing ZOLLER zidCode scanners at each machine in our shop. These scanners read QR codes from our ZOLLER Presetter, allowing us to automatically upload tool data directly to our machines. This not only eliminates manual data entry — a notorious source of setup errors — but also ensures that critical tool parameters are consistent and accurate across every job. Finally, to enable permanent, shop-floor durable tool marking, we have invested in a Haas CNC Laser Engraver. This will allow us to engrave QR codes and tooling information directly onto the tools themselves. Unlike temporary plastic tags or manual markings, these laser-etched codes provide a long-term solution for tool tracking and identification. Beyond Organization — Real Cost Savings Through Data & Efficiency While the organizational improvements of this project are significant, the true return on investment comes from the cost savings enabled by better data and process control. Tooling is expensive — both in terms of the tools themselves and the machine time required for setup and replacement. Tools break; accidents happen. But by capturing data around tool life and failure events, we can begin to analyze patterns and optimize our processes. For example, if a tool fails after a few days of service, that signals a serious problem — perhaps a setup issue, material inconsistency, or improper programming. Conversely, if a tool fails after months of use, that is likely within its expected life cycle. Without accurate tracking and history, these scenarios may look identical — but the

corrective action required is vastly different. Moreover, by leveraging tooling data, we can fine-tune our CNC programs for specific tools, adjusting feeds, speeds, and cutting paths to extend tool life and improve part quality. This level of optimization is only possible with accurate, real-time data — something that our new system will deliver. Tool Tracking: An Often-Overlooked Cost Factor Lost tools cost money — plain and simple. Especially in a facility like ours, where specialized tooling may only be needed once or twice a year, the ability to locate a specific tool quickly is critical. Too often, shops are forced to scrap jobs, purchase duplicate tools, or waste valuable hours hunting for lost items. Our new laser-engraved QR codes, integrated with the ZOLLER TMS, will provide clear visibility into every tool’s status — whether it’s new, in service, or nearing the end of its life. This level of tracking ensures that when we need a tool, we can find it — and we know its full history. The Road Ahead While much of the conversation around automation focuses on high-volume production or forging lines, our experience shows that even in a custom, low-to-mid-volume environment, automation and data-driven decision-making offer substantial benefits. As this project progresses, we are excited about the transformative impact it will have on our shop’s efficiency, accuracy, and customer service. By investing in automation and integrated storage, EST Tool is positioning itself not only to meet today’s challenges but to help lead our industry in the future. In an industry where every second of spindle time counts — and every tool matters — we believe our investment in automation and storage solutions will pay dividends for years to come.

Bailey Taylor Sales Associate

EST Tool & Machine, Inc. Email: Bailey@esttool.com Phone: 606-758-4626

FIA MAGAZINE | MAY 2025 33