2018 Lean Achievement Award

Submitted by: Kenn Bevins (Brazonics Inc. General Manager)- 02-23-2018

Team: Tool Connect

Achievement: Fool proof human error to using RFID (Radio Frequency Identification) ToolConnect
system

Owning Organization: Government Systems

Start Date: 3/2017 End Date: 10/2017

Testimonial: Robert Conley, George Kangethe

Team Leader: Robert Conley and George Kangethe Organization Level: Government System
Location: Hampton, NH Brazonics

Core Team members: Daniel Bevins, Jamie Conley (Summer Intern) and Peng Ann Chea

 Objective

ToolConnect was purchased from Caron Engineering to reduce the time it takes to do turn
overs a repeat jobs in the CNC (Computer Numerical Control) machines and also to make
it full proof process by eliminating human error. ToolConnect is a retrofit hardware and
software package for machine tools that eliminates human error and reduces setup time by
automating the transfer of CNC tool data to and from the control. The system is completely
customizable to meet customer requirements and tool load process specifications.

ToolConnect uses RFID tags that are embedded in tool holders. Utilizing a tool presetter, the
measurement data is written to the RFID tag. The tool is then placed in a custom RFID read
station at the machine, and the data is read and displayed by ToolConnect. ToolConnect
automatically updates tool offsets to the control. ToolConnect reads and writes data to the CNC
control; automatically updating tool offsets and tool life data to and from the tag.

 Initiation

Caron Engineering worked with Brazonics team to customize ToolConnect so the needs of
Brazonics customers could be met. Time was first spent on creating the program for each tool
geometry on the Parlec 1850 pre setter using the latest P7 software. This is a one-time set up for
each tool geometry used in our Akari Seiki 450i horizontal machining center.

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 2018 Lean Achievement Award

 Achievement

ToolConnect software implementation has been successful as it has reduced the manual labor on
the CNC as much as six hours per day. This software has also increased flexibility and
productivity as it allows us to set up several jobs simultaneously; and, it has eliminated the need
to over produce work in order to avoid set-ups. In addition, it has allowed us to share work
among employees with different capabilities without any risk of nonconformities.

Root Cause: Machines crashed often due to incorrectly manual tool information importing. This
was driven by the need to produce different part number on the same machine in the same shift.

Corrective Action: RFID to institute for electronic manual input into the control.

 Impact

This change has freed up employee time in the machine shop, allowing staff to complete other
items needed to meet demand. This change has created capacity of run time of the machine, as
the machine is not running while changing out tools. This has allowed us to run the right parts on
any shift, at any time desired according to machine scheduling. The RFID has reduced the
improper data input into the machine.

 Sustainability

A project leader has been chosen to ensure the project continues to move forward and
training occurs among employees. During the project a process instruction booklet was
developed to ensure correct use of the ToolConnect. On machines with this capability, it is
required to be used and cannot be used without ToolConnect. This is a permanent solution and
change to the machine electronics.

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