Efficiency Gains in Tool Monitoring at Schlote Group

Discover how Schlote Group leverages Softing's edgeConnector 840D to streamline tool monitoring in its metal machining processes, enhance transparency, and prevent downtime.

Challenge: Managing Tool Life Across Multiple CNC Centers

At nine facilities around the world, the Schlote Group operates an extensive machine pool for metal processing and other manufacturing processes. Drilling, turning, milling, and other cutting methods are part of the standard repertoire for processing engine, transmission and drivetrain components.

At Schlote’s Harsum facility in northern Germany, the machining tools for the production of steel components experience significant wear due to the high demands of metal processing. Each tool can perform a few thousand processing cycles before it must be replaced. On average, workers replace two to three tools every minute across the numerous machining centers in operation. Monitoring tool life across all machines to ensure timely replacements is critical for avoiding unplanned downtime caused by tool breakage. Schlote sought a digital solution to enable efficient and centralized monitoring of tool usage. 

Solution: Seamless Data Integration with edgeConnector 840D

The relevant tool cycle data is stored in the CNC controls of the machining centers. However, accessing this data in a standardized way across different machines is a challenge, especially since manufacturer-specific solutions often limit data transparency across machines from different manufacturers. Schlote found a solution in edgeConnector 840D from Softing Industrial, which extracts data directly from Sinumerik controls and transfers it to higher-level systems. The software is deployed as a Docker container on standard Windows servers with a Linux subsystem, ensuring easy integration into Schlote’s existing IT infrastructure. For older machines lacking Ethernet connections, Softing provides an adapter to enable communication through the serial interface. 

User-Friendly Data Visualization

The data collected by edgeConnector 840D is formatted into a structured process data tree and transferred via open industry standards such as OPC UA and MQTT. Schlote uses the Peakboard Designer to create visual dashboards for production teams. The low-code application enables the creation of complex visualizations without programming knowledge. Large screens installed throughout the production areas display the dashboards, making it easy for operators to see tool usage data at a glance. Unlike traditional machine status indicators, which only display colors, the dashboards provide detailed information about the reasons behind any status changes. 

Results: Increased Transparency and Better Integration

With the implementation of edgeConnector 840D, Schlote has achieved real-time transparency across its machining centers. The dashboards help the production team identify the exact moment tools need replacing, thereby preventing downtime and improving overall efficiency. The compatibility of Softing’s solution with the Peakboard visualization solution simplified the integration process. Schlote also benefited from Softing’s customer support, which enabled quick adjustments and ensured a seamless rollout. 

An extended version of this text was originally published in German in IT & Production Magazine and can be found here.

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