roi calculations
DESCRIPTION
This presentation is designed to help estimate the Return on Investment associated with adding Too ID. Visit the Balluff website for a link to the ROI Calculator. http://www.balluff.com/Balluff/us/ProductsChannel/Overview/en/Tool+ID.htmTRANSCRIPT
Return on Investment Calculations
Balluff Worldwide
Company Overview
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Balluff’s Core Business Offering the most comprehensive lines in the
Automation Industry!Our RFID Technology was developed as a result of our
inductive expertise.
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About Balluff
We are Global
Worldwide manufacturing, sales and service operations.
Ability to deliver consistent, excellent service across the globe.
2,400 Employees53 Subsidiaries/Representatives7 Manufacturing Locations
Balluff Worldwide Sales
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Industrial IdentificationRFID Tool Management Process
Machine tool
Machine tool
Tool lifemonitoring
Tool crib
Presetter
New tool
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The Process of Manual Tool Management
Operator enters data into Machine Controller
Load Tool into changer
Transport to Machining Centers
OperatorReads Tool data
and offsets
Potential
Problem Area
“1 error in 300 [keystrokes] in a manual entry mode” *
Possible Loading Error
* Kinkade, James D., “Using Automatic Identification Technologies for Logistic Support on Battlefields of the Future”, Thesis, Naval Postgraduate School, March, 1996.
Machine Center Side
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The Estimated Cost of Implementation
Cost of
RFID chips for tool holder$40
Cost of
Machining Center Upgrade$10,000
Cost of
New Presetter$75,000
Cost ofPresetter Upgrade
$4,000
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Industrial IdentificationRFID Tool Management Process
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The Process of Automatic Tool Management
Assemble New Tool
Measure Tool
Transport to Machining Centers
Document Offsets
Reasons for new tool are known…• Tool crash• Broken Tool• Normal wear• Excessive wear
Tool Room Side
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The Process of Automatic Tool Management
Load Tool into changer
Transport to Machining Centers
Machining Center reads tool information
Machine Center Side
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The Process ImprovementsExample: Information Tracked with each tool
Tool Status bits Tool in Use Tool Life pre-alarm Tool Life Expired Tool is broken Tool is locked Tool is in spindle Tool life deactive Tool has oversize
Data Value
Line Number (were tool is used) Head Line 4
Machine Number C21
Pocket Number 18
Tool Number TP305
Tool Serial Number 8397739
Geometric Tool Length 25.725
Geometric Cutter Comp. 35.225
Wear Tool Length -4.200
Wear Cutter Comp. 6.010
Tool Life max Counts 150
Tool Life warning Counts 125
Tool Life Remaining Counts 85
Preset Date (Time, Day Month, Year) 17:35, 20, 02, 06
Installed in Machine (Time, Day Month, Year) 15:22, 20, 02, 06
Removed (Time, Day, Month, Year 08:18, 18, 02, 06
Serviced (Time, Day Month, Year) 10:27, 18, 02, 06
Cycle Count 3066
Test Tool (Yes/No) No
Initial Comments None
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Industrial IdentificationRFID Tool Management Process
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Machine Tool
Cutting, chipping or grinding of metal requires rugged and reliable sensors
Ultra reliable RFID systems track tool data such as tool type, pre-setter offsets and usage history
Balluff Tool RFID guarantees 100% reliable every time due to our approach of doing double Reads or Read and Writes at each step in the process.
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The Process Improvements
Automatically track tool usage issuesEliminate possible misleading reporting
• Tool crash• Broken Tool• Normal wear• Excessive wear• Lost Tool Tracking• Machining Traceability
• Operator setup• Recurring setup problem• Base-line wear• Using the right tool• Proper Tool Processing Validation
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ROI Calculator
• Link to ROI Spreadsheet