Trumpf standardizes on tool data system

END USER: Trumpf Inc., (860) 255-6000, www.us.trumpf.com.
CHALLENGE: Boost production efficiency while reducing time, waste and cost.
SOLUTION: A tool data management system.
SOLUTION PROVIDER: TDM Systems, (847) 605-1269, www.tdmsystems.com.

German machine tool builder Trumpf GmbH + Co. KG, Ditzingen, began implementing a production resource management system several years ago to handle aspects of its “Synchro” system. The system features single-item flow assembly, including programming, simulation, uniformly integrated plant resources and tool data management. However, the system wasn’t multilingual, a major drawback for a multinational manufacturer, nor was it capable of client data management. Therefore, Trumpf began searching for a standard, full-featured solution for its global operations.

Trumpf was drawn to TDM Systems, Tübingen, Germany, following the adoption of its tool data management software by the Trumpf plant in Baar, Switzerland. (TDM Systems’ U.S. headquarters is in Schaumburg, Ill.) The tool data management system creates an integrated and transparent central database of tools and production resources that gives users the ability to save tool or manufacturer catalog data in a unified format at the component level, according to Trumpf. This information travels along with the tools throughout the production process to wherever it is needed.

Trumpf uses tool data management in building its machine tools, such as this TruPunch 3000 punch. The machine’s punching head is suitable for producing holes and making parts with 3D contours, such as threads.

The results of TDM software implementation at Baar were so convincing that the Trumpf plant in Grüsch, Switzerland, also implemented the system, followed a few weeks later by the Ditzingen, Hettingen and Neukirch plants in Germany. Rollout then proceeded for the rest of the company.

One key to the success of the rollout, according to Trumpf CAD/CAM Coordinator Axel Köhler, was TDM software’s ability to integrate with TopSolid’Cam, Trumpf’s CAM system.

“We generate tool data in TDM software, which gives all TopSolid’Cam users a uniform database for their programming and production simulation and the assurance of correct processing and technology data,” he said. In addition, TDM software’s data and graphic generator can create simulation-ready 3D graphic images, which are then imported directly into the CAM program, saving time and programming cost.

Another key factor in Trumpf’s success was the software’s ability to interface with its enterprise resource planning (ERP) system from SAP. “Just by itself, the interface from TDM software to SAP brings us an enormous gain in benefits at all our plants,” said Roland Göhler, group leader for large-part processing at Trumpf. “In the past, employees needed 20 minutes per tool to put data into the SAP system.”

Tool presetting is standardized at Trumpf and directly linked via an interface to the TDM tool data management system.

Now, he said, tool data can be stored according to use and new orders automatically triggered in SAP via the TDM/SAP interface when minimum stock levels are reached. When tools are added to the database, the required data for suppliers, prices and other key information is already on hand. Data exchange with ERP takes place automatically via the interface. Additionally, using the Trumpf material master data number, the user can transfer complete sets of SAP master data with a mouse click from one plant client to another.

The multilingual capability of the software and its server-client displays has also proved highly beneficial. Users work with screen displays in German, English, French and Czech. Chinese may be added, as a new Trumpf plant is slated to open in China.

The advantage of the server-client display is that an NC programmer is initially shown only tools available at his own plant. If he does not find a match there, the touch of a button widens the search to other plants. If the tool is housed in another plant, a mouse click is sufficient to requisition it, with the transaction recorded in the ERP system.

“Our cost pressure means that we cannot afford waste and unproductive activities,” Göhler said. “Once we have optimized setup times and introduced a machining process with the help of TDM software and transferred it to the other plants, we can simultaneously save time and reduce costs on many levels.”