Implementation of Tool Automation as Part of a Modern Manufacturing System
Kauhanen, Kalle (2024)
2024
Konetekniikan DI-ohjelma - Master's Programme in Mechanical Engineering
Tekniikan ja luonnontieteiden tiedekunta - Faculty of Engineering and Natural Sciences
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Hyväksymispäivämäärä
2024-12-13
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tuni-2024112110393
https://urn.fi/URN:NBN:fi:tuni-2024112110393
Tiivistelmä
This master's thesis examines the implementation of tool automation as part of a modern Flexible Manufacturing System (FMS). The study explores how integrating central tool storage and Tool Condition Monitoring (TCM) into the manufacturing process improves operational flexibility, reduces downtime, and optimizes tooling costs. By leveraging automation technologies and data-driven systems, the research provides a detailed evaluation of the operational and financial impacts of tool automation.
The findings reveal that tool automation significantly enhances production flexibility by eliminating manual tool handling errors and reducing setup times. Financial analysis indicates that the system has a payback period of approximately three years, driven by savings in investment costs in both machines and tools. Additionally, the TCM system was found to effectively monitor tool wear, though initial issues with false alarms required adjustments to the monitoring parameters.
This thesis also identifies key challenges during the implementation phase, such as system complexity and the need for operator training. Looking ahead, the research outlines potential areas for improvement, including optimizing tool movements and refining TCM systems to further minimize false alerts. Future research should focus on long-term performance analysis and comparing similar implementations across different industrial contexts to better understand scalability and broader applicability.
In conclusion, this study contributes to the growing field of smart manufacturing by demonstrating the operational and financial benefits of tool automation and central tool storage within a modern FMS, while also providing insights for minimizing tool breakages by monitoring tool wear in real time.
The findings reveal that tool automation significantly enhances production flexibility by eliminating manual tool handling errors and reducing setup times. Financial analysis indicates that the system has a payback period of approximately three years, driven by savings in investment costs in both machines and tools. Additionally, the TCM system was found to effectively monitor tool wear, though initial issues with false alarms required adjustments to the monitoring parameters.
This thesis also identifies key challenges during the implementation phase, such as system complexity and the need for operator training. Looking ahead, the research outlines potential areas for improvement, including optimizing tool movements and refining TCM systems to further minimize false alerts. Future research should focus on long-term performance analysis and comparing similar implementations across different industrial contexts to better understand scalability and broader applicability.
In conclusion, this study contributes to the growing field of smart manufacturing by demonstrating the operational and financial benefits of tool automation and central tool storage within a modern FMS, while also providing insights for minimizing tool breakages by monitoring tool wear in real time.