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DNC Software & Hardware – Peas in a Pod

dnc software hardwareDNC Hardware for CNCs

If you have recently made the decision to add DNC software to your shop floor to help with productivity and CNC communications, you are off to a great start.

Did you also know that adding hardware to DNC software solutions is the best way to leverage this business decision? Here are three pieces of hardware that best compliment DNC software:

Option 1: Wired CNC Connect. This device supports 100’s of CNC’s per each Server PC that has a seat of DNC software on it. Simply run Ethernet cable to each machine and place the device on the control for drip-feeding. The IP address converts into a comm port with drivers. By using the network backbone, you are sending the serial signal five feet wth the supplied cable, giving you the most reliable and strongest serial signal. Available in 1 to 16 ports.

Option 2: Wireless CNC Connect. The best option for those who like to move machines around and change the layout of their shop floor often. No cabling required. The device comes with an assigned IP – just to add your network, properly mount the device and it’s ready.

Option 3: Multi Connect. While this device is not available for purchase yet, it is anticipated to be a ground-breaking piece of hardware for manufacturing shop floors. The unit connects to machines via MTConnect, PLC, Wireless, Ethernet, and RS232 Serial. This solution can also be used with DNC Software and Machine Monitoring products, which makes it very versatile.

What are the best DNC software options available? Check out Predator DNC, Predator Touch HMI, Predator EditLock, and ExtremeDNC by visiting our DNC software landing page!

Not sure what DNC Software is or why it would benefit you? Check out why some customers use DNC. You may also call (877) 611-5825 for more information about any products in this post.  

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MFG Costs, Budgets & Integration ROI

mfg costs mfg budget mfg integratorManufacturing costs are a pain.

MFG costs and budget comes into play whenever productivity improvements are considered. Costs are sadly not predictable.

There are four variables of expenses when running a manufacturing company. We have broken it down into a driving analogy for our readers:

Fixed Costs: You get in your car, you set up your GPS and map out the trip to avoid tolls. You know how much time it will take to get there and how many miles.

Fixed costs are part of the routine in manufacturing. These cover utility bills, taxes, property costs, and salaries (not counting commission). This also includes office supplies, too.

Variable Costs: When you plan to take your trip, you account for normal traffic patterns that will add a likely delay. It’s an annoyance we have come to both accept and expect for road trips.

Variable costs can best be described as costs directly in relation to production. For example – when you produce more, you ultimately need more raw materials. These patterns are predictable –  remember the old saying “you gotta spend money to make money”?

Semi-Variable & Step-Variable Costs: When you’re on your trip, let’s say a horrific accident happens, or you hit an unexpected detour. These unforeseen but likely scenarios can add time to your trip.

Semi-variable costs account for costs that can vary. This includes commissions for salespeople or production-based bonuses.

Step-variable costs, however, are costs that remain fixed for a period of time, and can suddenly spike up. Unexpected machine downtime, for example, costs money due to stopped production. You may even have to hire a specialist to come out or replace it with another machine.

What is the common factor in all of these examples, though?

If you invested in the GPS, it will reroute you, or add time to your route when you hit traffic or unexpected snags in the road. It is monitoring conditions for you to give you expectations and suggestions on how to improve your route.

How does this relate to manufacturing integration solutions & ROI?

Investing in manufacturing integration solutions is the best ROI when taking into account situations that lead to step-variable costs in your production. It’s essentially giving yourself a GPS to help meet and exceed production goals.

If your machines are consistently having communication errors that cause thousands of dollars in stopped production time, then DNC software or hardware is a drop in the bucket to help prevent this from happening. If there are other issues with machines causing downtime that are not relative to CNC communication failures, then machine monitoring can help for better OEE and for machinists to better communicate issues for proper solutions.

Get in touch with Shop Floor Automations for more insight! You can fill out a form here, or call us at (877) 611-5825. 

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New Manufacturing Techniques

People try out new technologies each day. The manufacturing industry is no exception.

They buy new phones, lease new cars, upgrade the software on their phones and computers, or add implements to their homes to improve their quality of life. Embracing new technology is a move that would benefit the manufacturing shop floor industry most.

A woman stands at the airport looking at 3 machine monitoring screens related to the status of her machine at the shop. A blue text bubble coming from her backpack says "Text: Downtime. Machine 2. Department notified."Here are the Top 3 ways that new manufacturing technology adopted on the shop floor can benefit your company:

1 – You can keep up with the competition. According to recent results from the Manufacturers’ Outlook Survey, the National Association of Manufacturers states that in 2017, there is a record-high level of optimism in the manufacturing industry. 91.4 percent of manufacturers said they would increase investments, hire more workers, and that they generally feel good about our industry’s growth. Do you fit in this category?

Are pieces of old tech, like floppy disk drives and handheld terminals holding you back? Are you experiencing communication failures due to lack of CNC memory for your programs? These are all problems that new technology can fix, so that you can get in on this wave of prosperity.

2 – Increase profit. When implementing new hardware and software into older machines, this can help drastically decrease downtime. When there is no downtime to deal with, or less of it, machinists are free to perfect their craft. According to SME, there have been proven studies that show on average, time will decrease 5 percent every time the number of completed pieces doubles.

Therefore, if a machinist has more time to actually do their job than deal with machines going down, that will ultimately make the company more productive. Implementing machine monitoring to track machine trends increases OEE and DNC software can help with CNC communication failure, which are two sure fire ways to combat downtime.

3 – More freedom. When there is less worry of machines going down, this can create a better work/life balance for those who work on the shop floor, and in the front office. Machine monitoring, which is a powerful IIoT (industrial internet of things) tool, is an amazing way to get notifications of what is going on with machines not only on the shop floor, but via email or text notifications.

When this proven solution to deal with downtime is combined with more accountability through the means of graphical job scheduling, PDM, and other resources on the shop floor, there is more trust in the workplace. More people can use their PTO to go on vacation, or workers who are home sick can help give guidance when a machine goes down via a notes section through machine monitoring.

If you are interested in new technology for your shop floor and experiencing the benefits listed above, contact us by filling out a sales form here, or call (877) 611-5825.

 

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Cloudy with a Chance of OEE

OEE, IIoT & The Cloud

“By 2020, a corporate ‘no-Cloud’ policy will be as rare as a ‘no-internet’ policy is today.”

This is a bold claim from Gartner, a respected information technology research company. Cloud IIoT Security is becoming a major concern in the manufacturing industry.

A textless web chart symbolizing the Internet of Things centralized within a cloud database.Shop Floor Automations is a big proponent of Cloud tech, especially in terms of the Industrial Internet of Things, or the IIoT. One of our hottest sellers is DataXchange from Scytec, with its $45 per month per machine pricing policy for Cloud-based services. We also realize that secure drip-feeding is a concern of note, as well, in the manufacturing community.

For those who are apprehensive about adopting IIoT Cloud tech or any kind of software/devices to help with drip-feeding via DNC Software, here are three resources to help you make an informed decision:

Cloud tech is more reliable than you previously thought.  A publication called Enterprise Tech states that Global IT spending should increase close to 3 percent in 2017 – the projected $3.46 Trillion spent this year on worldwide IT is in part due to the Cloud infrastructure being so significant, as time goes by. In keeping with this fact, Cloud-based machine monitoring has helped many of our customers. One such manufacturer has even been able to run their existing five-axis CNC machines for 24 hours at a time at increased productivity, rather than feeling the need to invest in more machines to achieve their production goals. That definitely speaks to the trust of this Cloud-based program!

Implement a cybersecurity assurance program along with your Cloud solutions. The Cybersecurity Assurance Program (UL CAP) for industrial control systems from a global safety science organization UL was introduced for in late 2016. “UL CAP is intended for control system manufacturers who need support in assessing security risks while they continue to focus on product innovation to help build safer, more secure products,” states Mark Albert from Modern Machine Shop. “These steps will help protect the Industrial Internet of Things (IIoT). The program should benefit OEMs, machine tool builders, system integrators, and retrofitters who want to mitigate risks by sourcing products assessed by an expert third party.”

Secure DNC makes DNC software communications safer.  This is a Windows application designed to be installed on Windows-based CNC machines, CMMs, test stands, and other equipment. This application from Predator DNC supports a wireless or wired Ethernet interface via TCP/IP. It not only supports older versions of Windows, which reduces the need for costly Windows updates on CNC machines, but it is also a good measure against unauthorized access via hackers. Read more about Secure DNC here.

Ready to get started? Contact Shop Floor Automations for better, and safer, OEE through IIoT. Call (877) 611-5825 or contact us on social media! 

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What is Predator Secure DNC?

What is Predator Secure DNC?

If you invested in DNC Software, you want to know your programs are secure, as well as organized. How many of your newer machines are just plugged into the network?

Introducing, Secure DNC. It’s a Windows application designed to be installed on Windows-based CNC machines, CMMs, test stands, and other equipment.

This application from Predator DNC supports a wireless or wired Ethernet interface via TCP/IP. It eliminates the requirements of corporate domains, workgroups, or Windows Shares for DNC transfers.

Secure DNC also supports older versions of Windows, which reduces the need for costly Windows updates on CNC machines. “The best way to explain how it’s helpful is that it allows secure file transfers to CNC machines through firewalls,” said one of our technicians at SFA.

“For example, if a shop has Windows-based machines and strict network security, they can send directly to the hard drive of the machine,” they explain. This does not interfere with the network and does not create additional security risks.

Another one of our techs also added that “you no longer need to share unsecured folders on machines.”

Using Secure DNC, which is a component of Predator DNC Software, is a beneficial combination for your shop floor. Here is what some of our customers had to say about Predator DNC:

We have experienced faster, easier [CNC] file transport. -Daniel, Benét Laboratories for the US ARMY

Needed to be able to communicate our CNCs and improve the ability of our mill.  -Shane, Power Repair Service Inc

Looking for a system that would communicate through a wireless network, so we could get rid of the switchbox and old wires running all over the machine shop. -Rajikumar, Nell Joy Industries

Want more info? Call us at (877) 611-5825. You can also request more Predator DNC info via this Sales contact form.

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Why Customers use DNC Software

dnc software and multi dnc softwareWhat is DNC Software?

Aiding in the process of Direct Numeric Control (sometimes considered Distributed Numeric Control), DNC software helps with total shop floor control. Via our DNC Communications page:

Manage your CNC programs, machine parameters, & offsets with DNC Software. Enjoy a wide range of CNC communication options from your PCs for drip-feeding, downloading, & bi-directional communication. Upload via parallel, RS232, RS422 Ethernet, & wireless Ethernet for thousands of CNC machines. With Microsoft Office  & Windows Explorer-compatible user interface (Windows 10 O/S supported), use familiar features for drag & drop, cut, copy, paste, shortcut menus, object-based menus, toolbars, tool tips, & available online help.

Improve CNC revision control while using existing ERP & MES bar-coded paperwork. Eliminate time wasted walking back & forth between your CNC & PC with a Remote Request function. Consider a 32-Bit, Multi-thread, Multi-tasking, Open-Architecture DNC Software solution that works wired & wirelessly. Simplify operations with one network for all of your CNC machines, Robots, PLCs, & part makers, grouped by building or cell.

Now that we have a window into what DNC Software can do, why do some customers use DNC Software?

My old CNC communication network had failed. I could not send files to my CNC sometimes for hours, then it would randomly work. Because of the intermittent failure, we kept trying for a long period of time to keep using our old system. After measuring the time loss for system failure, it was clear we needed to change it out. Now we can even send files via DNC which before did not work as it was supposed to have. –Michael, Mini Machine

Our programs were so large that we couldn’t download them onto our machines, so we started using a drip-feeding system from you guys. Then, we changed over from there to now doing a data server on our machines, but we’re still using your guys’ software (DNC through SFA) to build all of our programs.  -Josh, HRE Wheels

Our DNC system is running so well, that after over 2 years, I have moved the keyboard and monitor off my desk and into a corner. It requires no maintenance and provides us with a trouble-free system. – Mark, Tech Manufacturing

We were trying to control over 8000 programs, revision levels, and updates – the Predator system was recommended to help minimize the man hours and mistakes of doing this manually. We installed DNC and a CNC Editor, and have had no downtime with full control. CMW currently manages approximately 8000 part programs. The system seems to be indestructible – we have had no problems. -Wayne, Carroll Machine

I sought out SFA mainly for DNC for our CNC machines. We have experienced faster, easier file transport. -Daniel, Benét Laboratories for the US ARMY

We needed to be able to communicate our CNCs and improve the ability of our mill. I’ve been using DNC through you for a long time.  -Shane, Power Repair Service Inc

We were looking for a system that would communicate through a wireless network, so we could get rid of the switchbox and old wires running all over the machine shop. DNC Software helped us eliminate our old switchbox…The customer support was great. They were very supportive and fixed errors quick when we had a couple of problems. -Rajikumar, Nell Joy Industries

Read more customer reviews on DNC, and other products, via the SFA customer testimonials. Look at our free DNC software resources, or if you are ready to make a purchase, call us at (877) 611-5825. 

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SFA New Product Released in CNC West Magazine

Predator DNC V10 Released – original article from CNC West Magazine: 

Predator DNC SoftwareShop Floor Automations (SFA), one of the largest independent CNC automation suppliers for Predator Software has begun implementing the latest version of Predator DNC Software v10. The new version continues to improve support for the latest CNCs, robots, PLCs and other manufacturing equipment under the latest version of Microsoft Windows. Numerous new features and improvements have been added.

The support for MicrosoftWindows 8, and Server 2012 has been completed under 32 and 64 bit operation systems while including Predator DNC Objects for Microsoft SQL for 2012 and 2014. The new version extends the support for virtual operating systems such as VMware and HyperV.

Predator DNC v10 supports the latest Fanuc Focas v3.9 device drivers. The change improved support for Fanuc controls with new options to eliminate spaces in filenames, automatically rename to an O number and force uppercase files. The new drivers enable support forWindows functional account providing specific permissions to access target folders to help secure CNCs from network.

Additional diagnostic tools have been created to allow users to support a machine specific error log without enabling multiple commands and individual logs. A single log created to trace all activity and shared to multiple users for confirmation of transfers and historical archiving. Shop Floor Automations reports the benefits of upgrading the Predator Software to the latest version allow for future compatibility between enhanced wireless and wired serial devices used for CNC communication and machine monitoring applications. The Predator Editor Lock provides software control over a CNC machines “Write Protect” key to lock and unlock the CNC’s memory.

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Predator Software Version Upgrades Released

Predator SoftwarePredator Software Version Upgrades

At the end of 1st quarter of 2015, Predator Software has released v10 product suite.

Over 115,000 companies in over 40 countries rely on Predator solutions to network, monitor, revise, control, organize, verify, manage and automate their shop floor and improve productivity. Users are now able to upgrade to the latest versions to support Windows 8 and Server 20012, with enhanced support for virtual operating systems.

Predator Machine Monitoring and Data Collection included several new features: two new OEE dashboards, bar charts for good/scrap parts, 4 new components (cost centers, work center, machine type and report type), chart filters, and 125 machine time reports.

To learn more about the services Shop Floor Automations provides, which includes Predator, we invite you to check out our YouTube channel for tutorials, insights, and more. Visit our YouTube channel, and see our video’s technical guides AKA transcripts.

SFA is also located on other social media channels, such as Twitter, Facebook, LinkedIn, & more!

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DNC Software for FANUC Controls – Part 1

DNC SoftwareDNC Software for FANUC Controls

Many clients call us about DNC Software for FANUC controls and ask “can I DNC or drip-feed my FANUC control?” The typical response is “what model of FANUC control do you have on the machine that you want to use the DNC software with?” Many times, the specifics are not available, but solutions are available depending on the make and model of the FANUC control!

To drip-feed or DNC to FANUC controls, there are several requirements that need to be met. For this post, assume this is a FANUC older controller with a tape reader. The old model of Fanuc controls had a switch or toggle on the controller that allowed for the operator to enable tape mode, along with other modes like MDI and Edit. When in the tape mode, the part program is executed line by line (more happens but keeping this post short). The operator would load up the tape on the machine’s tape reader and press Cycle Start to cue the part program.

Today, tape readers are a thing of the past and these FANUC controls still need DNC Software to drip-feed. For an older FANUC control that needs to be drip-feed or DNC, we can supply a Behind the Tape Reader (BTR). The BTR and DNC Software will replace the old tape reader and “trick” the control to believe it executes the old tape. If you have executives tapes, no problem – the DNC Software for the FANUC control can be configured to accept this as well.

There are many options for DNC Software for FANUC controls, but the key is compatibility and ease of configuration to work with Windows 7 and 8. Our motto is to keep it simple and don’t try to find the cheapest solution. Sometimes, you will spend more time trying to troubleshoot the FANUC drip-feed problem when something elsewhere is already proven and reliable.

Find a vendor who has experience and can provide you with the complete solution for DNC Software for the FANUC control. We would love to hear from you to help you with your shop floor needs!

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Predator DNC Software and Ascendant eXtremeDNC Software Compared

DNC SoftwareDNC Software features compared

Predator DNC software and Ascendant eXtremeDNC software are two great tools for CNC networking of different CNCs, punch press, waterjets and other industrial equipment. They are each used to manage different types of programs. Ascendant eXtrmeDNC was the first DNC open architecture application for the 32-bit Windows operating system. It was first introduced in 1993, upgraded in 2010 to make it compatible with modern operating systems, and adapted to Ethernet, wired, and wireless hardware. It was developed for Windows NT 3.5 but with the modifications, it could be applied to some modern operating systems other than a Windows based OS. It works best in a Windows 7 or Server 2008 operating systems.

However, the introduction of Predator DNC software revolutionized the CNC and DNC world. This is because of the enormous multitasking functions that can be performed on it. It has more capacity to upload, download, and drip-feed. Just like the Ascendant eXtremeDNC Software, Predator DNC Software has wireless and Ethernet support. Predator DNC also uses a “object-oriented” tool library to build on functionality as the user desires. The solution also allows for a full upgrade path to other modules, such as machine monitoring, product data management, and tool rib management. While eXtremeDNC has connection ports that could serve 1023 communication networks at a time, Predator DNC Software has 4096 connection and it can be used with 4096 machines simultaneously. This gives it more networking capacity.

extremedncStill, eXtremeDNC software is a useful tool, it serves different purposes for its users. It is a smart architecture compliance server which supports transmission and effective maintenance of files. If a server failure occurs or there is a loss of server networking file transmissions are not disrupted.

EXtremeDNC does not require a lot of setup and configuration. Out of the box, the product comes with several CNC templates ready to communicate to the machine tool The software enhances functions such as email notifications, it facilitates the auto tag, and renames standardization. It also enables control and easy integration of third party software. Another great aspect to eXtremeDNC Is the client/server functionality that provides true, real-time feedback as to the status of transfer. The licensing is flexible as well to purchase only the ports needed and floats without any additional modules. Read more below.

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