The Tools functionality in Manufacturing is very flexible and can be used for the following:
- Setting up the tools that will be used in the manufacturing process (the production of a manufacturing order).
- Preventive service – planning the maintenance (calibration) of the tools, thereby improving the quality of the tools by being able to determine, in advance, how often the tool should be calibrated.
- Tracking the usage of the tool per product, operation and/or manufacturing order.
- Defining the cost of the tools – to eventually be updated in the Product costing module.
When you set up the different tools, you can decide to use all or some functions.
Note: You set up all information via one program. However, to better understand the flexibility of the Tool functionality, the tasks depict the different functions individually. See the Related topics.
Calibration process
The tool calibration function is related to preventive service. Using this functionality you can plan in advance how often the tools should be calibrated, thereby improving the quality of the tools.
For the calibration function to work a number of calibration rules have to be defined for the tool. The Calibrate field on the Tools and fixtures maintenance panel defines if the tool should be calibrated. The calibration identifiers on the same panel define how often and when the calibration should be done.
When you want to start the calibration you print the calibration report to find out what tools are in need of maintenance. When the calibration has been performed, the result is reported in the calibration reporting routine.
The calibration process steps are connected to a calibration status. The calibration status field is updated by the system and indicates where the tool is in this calibration process:
| Status | Description |
|---|---|
| Blank | Normal status. The tool is not under calibration. |
| 1 | Printed for calibration. The status is automatically changed to 1 when the calibration report has been printed. |
| 2 | Calibrated. The status is automatically changed to 2 when the calibration result has been reported. |
| 3 | Held. This status can only be entered manually for the tool. When a tool is held it cannot be calibrated. However, it can still be used in the operation. |
Tip: The calibration status can be manually changed. This can, for example, be useful if you want to calibrate a new tool directly instead of waiting for the calibration point or date to be reached.
Calibration identifiers
The calibration identifiers determine how often and when a tool should be calibrated. Some of the calibration identifiers are controlled by points and counters and others are controlled by dates. The following calibration identifiers exist:
| Identifier | Description |
|---|---|
| 1 | Hours. Value for hours is Set-up time internal + Machine hours, or if machine hours is not used for operation, the run and labour value is used. |
| 2 | Produced pieces. Value for produced pieces is Approved quantity + Scrapped quantity |
| 3 | Number of operations. Value will be updated when the manufacturing order operation is changed to status 40 (started). |
| 4 | Weekly calibration |
| 5 | Monthly calibration |
| 6 | Defined calibration dates |
Calibration controlled by point and counter
The calibration identifiers of type 1 (hours), 2 (produced pieces) and 3 (number of operations) require a calibration point that indicates when the calibration should begin. You define per tool what this point should be.
During the operation reporting of a manufacturing order, you report the relevant machine hours, produced pieces or number of operations. The system automatically updates these values in the Calibration counter field within the Work with tools and fixtures program. When the Calibration counter reaches the same value (or has exceeded the value) as that in the Calibration point, it is time to calibrate the tool.
Calibration controlled by dates
The calibration identifiers of type 4 (weekly calibration), 5 (monthly calibration) and 6 (defined calibration dates) are date-related. You define per tool if the calibration should be done every week, month or at pre-defined calibration dates.
- For calibration identifier 4 (weekly calibration) and 5 (monthly calibration), you define the first calibration date in the Next calibr date field in the applicable tool information. The system will then automatically calculate the next calibration date according to the selected calibration identifier.
- For calibration identifier 6 (defined calibration date), you must access the applicable tool information in change mode and click Calibration dates to select the applicable calibration dates for the tool.
See Set up calibration rules for a tool for instructions about how to set up the calibration identifiers.
Calibration printing
You should periodically print a calibration report to track the need for calibration. This can only be done once per day and tool.
During the printing of the report, the system will flag the tool as being under calibration, and consequently set the calibration status to 1 (printed for calibration).
The calibration report displays the tools that are in need of calibration:
- For tools that are controlled by points and counters, the report outlines the tools that have exceeded the calibration point.
- For tools that are controlled by dates, the report outlines the tools that have exceeded the calibration date.
See Track the need for calibration of a tool for instructions about how to print the report.
Calibration reporting
When calibration has been performed for a tool this should be reported in the calibration reporting routine. The following takes place in the Work with tools/fixtures program when you have accepted the reported values for the tool:
- Last calibr date is updated to the date you accepted the results.
- Next calibr date is updated to the next applicable date when a calibration should take place for those tools using the Date method.
- Calibration counter is reset to “blank” for those tools using the Point/Counter method.
- Calibration status is reset to “blank”.
See Report calibration results for instructions about how to report the calibration result.
Enquiries and printouts
- Allocation enquiry
Accessed via the Work with tools and fixtures program. Use this enquiry to view the tool allocations by date, thereby being able to see on which manufacturing operation the tool is allocated. - Calibration history enquiry
Accessed via the Work with tools and fixtures program. Use this enquiry to view the historical calibration results of the tool. This enquiry can be helpful in determining the need for, e.g., a total re-haul of the tool, a simple re-calibration of the tool or even a new purchase. - Material/Capacity clearance enquiry
Use the Capacity clearance enquiry to monitor the workload and free capacity of the work centre and tools. - Tools/Fixtures report (TOOL_REP)
Accessed via the Work with reports/jobs – MFG Basic data menu item. Print this report to view the basic data of the tool. - Calibration planning report (TOOL_PLAN)
Accessed via the Work with reports/jobs – MFG Basic data menu item. This report is optional and can be used to determine the tools that should be calibrated in the future (the tools that will soon exceed the calibration point or calibration date – depending on what method of calibration you chose). - Calibration report (CALIB_REP)
Accessed via the Work with reports/jobs – MFG Basic data menu item. Print this report to see which tools have exceeded the calibration point or calibration date – thereby knowing which tools you have to calibrate.