Is a specialized database application used by the

manufacturing industry to reduce production costs by controlling

tool usage, inventory, rework and purchases.

Reduces production costs by:• Reducing tool inventory• Eliminating unknown tool quantities• Eliminating duplicate tooling• Eliminating poor tool storage practices• Reducing crisis tool changes• Optimizing tool life• Eliminating unreliable tool data • Minimizing down time• Increasing part quality

Variset 4 - Comprehensive Tool Management Features & Capabilities

• Central data repository• Options and privileges are configurable for multiple security

levels .• Easy import, export & creation of data• “At-A-Glance” Inventory management• Serialization – Auto generate or user specified• Rework tracking and management• Tool presetting & gauge interface• Scheduled & unscheduled tool change register and reports• Automatically sends e-mail & pager alarms•Can link to customer’s material requisition software• Tool costing – Unique to the industry• Works with bar code equipment & RFID code tags• Extensive browser based HELP

Keep Track of All Scrapped Items

Issue Tooling to the Factory Floor and

Monitor its Useable Life.

Total multiple crib monitoring and

management

Electronically Place New Orders and Keep

Track of Receives

Alarms

V4

Storage Place Orders and Receive New Items

V4

Factory Floor Tooling

V4

V4

Scrap

Send Components to Rework and Log Rework Statistics

Automatically Send Stock and Tool life

Warnings

Variset 4’s ProcessRework/PresetV4

System Overview

Variset 4 - Fully Configurable Security Levels

Variset 4 supports multiple languages

Users can log onto specific lines

Security level is based on user name

Categorized menu bar:All menus are customizable,screens may be locked out at

user/security levels

Large customizable button screen allows

rapid access to screens

Variset 4 - Easy to Navigate Buttons and Menu’s

Create and edit itemsImport &

export dataGauge tools

Variset 4 - Effortlessly Create & Edit Items

Item list

Item Navigator Search tab can filter items by

multiple criteriaItem type drop down list. Choose from Components, Tools, Kits, Containers

or the Variset Tree.

Category drop down list can automatically configure the information tabs for inventory,

rework and tool life tracking

Item information

Search through the plant structure with the Variset

Tree.Displays the tooling data in a way familiar to plant floor

personnel.

Help ButtonFunction Buttons:

Save, New, Copy, Rename, DeletePrint Button:Prints all the data for the

selected item

Wildcard search field LineOperation

Components in tool assembly

Unique location

Item number(Kit)

Info

Create/Edit

Customizable item specific

fieldsTool

assembliesin the kit

Variset 4 – Add Build-up for Assembly

Associate items together for assemble, disassemble and

inventory transactions.

These are all the components that make up the selected tool

assemblyDouble click on a component

to access its create/edit screens.

Build-Up

Create/Edit

Variset 4 Supports Multiple Graphic Formats

JPEG

GIF

CAD TIF

WMF

PNGBMP

Drawing

Create/Edit

Variset 4 – “At a Glance” InventoryPermits Easy Set-up of Inventory Centers

Define and view multiple inventory

locations

Sends high & low stock e-mail and pager alarms

View quantity at a location

View total plant quantity

View high & low stock quantities for each

location

Inventory

Create/Edit

Variset 4 - Calculates Tooling Costs

Tracks tool cost based on a departments actual consumption.

(Its portion of the tool usage)

Also allows for adjusting costs based on changes in current pricing.

Cost

Create/Edit

Variset 4 Interfaces with Royal and Other Presetting Gauges

Comprehensive data for proper gauging of tools

Nominal screen categorized and tabbed for easy maintenance of

gauge data

Nominal

Create/Edit

Variset 4 – Gauge Interface

• Full integration with Royal’s presetting gauges

• Full Functionality of the Industry Standard Variset III

• Real time gauging Screen

• Flying Box® edge location

Variset 4 - Complete Inventory Management

Inventory screen menu

Multi-Action Assemble/Disassemble/Rework:Floor to crib to rework, receive, scrap & container transactions

Rework:(Cutter grind management)Rework to crib transactions

Scrap:Removes items from inventory

To/From Rework:Crib to rework transactions

Check In/Check Out:Floor to crib transactions

Receive:Receive items into inventory

Assemble/Disassemble:Crib to floor transactions

Inventory

Variset 4 -“Receive” Inventory Screen

Quantity before receive

Quantity after receive

Receive to any inventory center

Quantity to receiveSelected component

Component information

“At a Glance”inventory buttons

Transaction button

Inventory

Variset 4 - “Multi-Action Assemble” Inventory Screen

Automatically receive needed

inventory

Pull stock from multiple

locations.

Assembled Kits “To…” location

Components “From…” locationMonitor component

quantities available

Inventory

Variset 4 - “Multi-Action Disassemble” Inventory Screen

Kits“From…” location Non-Rework tracked

components go to “Crib”

Tracked components go to

“Rework”

Or, send components to different locations

Scrap components

Receive components

Inventory

Variset 4 - “Rework Center” Inventory Screen

Date/Time stampfirst in rework

Quantity in rework

Selected rework center

ScoreIncrements for priority above

Date/Time stamp

Assign item to a person or machine

Component/Container information

Inventory

Variset 4 - “Rework” Inventory ScreenSerialized Components

Color coded for warning and limit levels

Component information Quickly access additional information or drawings

without leaving the rework screen

Select an option from the drop down list,

“Move” or “Scrap”.

Warning and limit levels to prompt for scrapping

of overworked components.

Serialized tab is only accessible for serialized components

Inventory

Number of components being moved

“Move to…”location

Total quantity in rework

Automatically moves containers and all associated

components.

Scrap componentsfrom rework

Variset 4 - “Rework” Inventory ScreenInventory

Variset 4 - “Reports” Menu

Extensive Reporting Capabilities

Reports

Variset 4 - “Reports” Screen Filters on Multiple Criteria Providing Increased Reporting Flexibility

Report on a date rangeReport on a Department/Line/Operation

Report on an individual item

Reports

Variset 4 - Sample Reports

“Tools Not Changed Report”

Shows the top 10 tools that have not been changed and

graphically displays the top 5 reasons.

“Unscheduled Tool Changed Report”

Shows the top 10 tools that have had the most unscheduled changes and

graphically displays the top 5 reasons.

Reports

Variset 4 is configurable for both Comparative or Predictive tool life:

• Comparative:• Allows for tool change alerts to be signaled

based on reported production counts.• Maximizes tool life.

• Predictive:• Allows for tool change to be scheduled based

on reported production counts, expected future production counts, and the production schedule.

• Maximizes Production Up-time.

Variset 4 - “Tool Life” Screens

Items scheduled for change

Handles tools with multiple edges and varying expected

counts

Unique locations

Change:Tool has reached its

expected life and needs to be changed

Pull:A different part is to be run on the line. Pull the tool assembly from the

unique location and leave empty.

Fit:A different part is to be run on the line. Fit the tool assembly into the empty unique location

Sends tool change e-mail and pager alarms

Item’scurrent count

Item’spredicted count at change

time

Accommodates multiple parts machined on the same line.

Prompts personnel toChange/Pull/Fit

Tool life

•Auto Pilot Feature: (Comparison & Predictive)•Tool change frequency can be adjusted automatically using actual tool performance data collected. • Parameters for adjustment are definable by the user for each tool.

Variset 4 - “TCS” ScreensDesigned for the Factory Floor

Perform scheduled tool changesPerform unscheduled tool changes

Floor personnel can view the current tool counts

TCS screens aredesigned for mouse,

touch screen ortablet PC’s with

wireless network connection.

Variset 4 - “TCS Current Counts” Screen

Operationbeing viewed

Color coded fields for easy identification

Department/Linebeing viewed

Variset 4 - “TCS Unscheduled Change” Screen

Pick the button to process all tools with a change reason

Select reason for tools to be changed

Definable unscheduled change reasons

Variset 4 - “TCS Scheduled Change” Screen

All tools will be changed unless the operator selects a “Not

Changed” reason

Pick the button to process all tools without a “Not Changed”

reason

Definable not changed reasons

Royal’s automatic RF ID tag read/write station

Variset 4 – Supports Bar Code & RFID Code Tags

Tool holder

Read/Write head:Read/writes the data to and

from Variset 4

Tool holder RFID code tag(Not visible)

Scan bar codes to receive, scrap and move

items to and from inventory centers.

a

Examples of RFID code tag data:• Tool number• Tool holder serialized ID• Preset length (up to 4 edges)• Preset diameter (up to 4 edges)• Machine pocket number• Running totals per cutting edge• User definable fields

RFID code tagRead and write RFID code tags to pass tooling data to and from CNC machining

cells.

Variset 4 – RFID Code Tags

In create/edit the tool ID button brings up all the tools with a

tool ID micro-chips and selects proper tool.

On the rework screen the tool ID button brings the

component number

And, brings up the specific serialized component

Inventory

Variset 4 – RF ID Code Tags

Variset 4 does not allow un-maintained components to

return to the floor.

Inventory

Variset 4 – Extensive HELP Documentation

“How to” instructions

Hyper-linked image maps to quickly

move to the area of interest Hyper-links to

definitions

Help Document contains:

• Hyper-links to related topics

• Content sensitive index and search

• Training with Screen Cam® movies

Help

Hyper-links to instructional videos

Content sensitive search

Variset 4 – Extensive HELP Documentation

Sample Screen Cam® movie

Help