Session: 2018-2022

What is a CNC Machine?

CNC stands for “computer numerical control.” These machines represent a manufacturing
process used to control a wide range of complex tasks.
CNC machining is used in many different industries. It’s most prevalent in metal and plastic
production.
Basically, CNC machining is a manufacturing process. Computer software is pre-
programmed to tell a machine how to move factory tools and machinery.
A CNC machine allows for three-dimensional cutting tasks to be accomplished with a single
set of prompts. This means that it requires very little input from human operators.
Once the programming is put into the machine, a CNC machine will operate on its own. The
speed and position of machinery and involved tools are run through software. CNC machines
operate like robots.
How does CNC Programming Work?
CNC machining relies heavily on programming. A human programmer must input the right
codes and ensure they work properly. Without the codes, there is no CNC machining.
The language behind CNC machining is also known as G-Code. Most manufacturing
machines have code to dictate one or two functions. G-Code is significantly more complex
than this. There are also M-Codes and some other types of codes as well.
G-Code will control many varying behaviors in CNC machines. These include speed, feed
rate, and coordination.
Once G-Code is written and fed into the machine, there is almost no need for human
operators. The code does most (if not all) of the work for them.

What Is Industry 4.0?

Industry 4.0 refers to the fourth industrial revolution. This revolution uses data and cloud
computing for production and manufacturing. The Internet of Things, specifically the
Industrial Internet of Things (IIoT), along with artificial intelligence and computer integration
are the core components of Industry 4.0.
These new technological developments automate many processes of manufacturing, creating
a “smart” facility. Each system can communicate with each other and share data, which
results in quicker turnaround times and savings on costs.
The Driving Factors of Industry 4.0
There are three driving factors for Industry 4.0:
 Integration
 Data collection
 Customer success
These drivers share two things: data and analysis. The goal of all this interconnectivity is to
automate and streamline processes, which can’t be done without the proper data collection
and analysis. It’s more than just a way to manage your CNC machine shop; it’s a way to run
your entire business.
Industry 4.0 relies on digital technology to function, specifically instruments and machines
that can sense, monitor and respond autonomously to physical processes. A few examples of
this are GPS sensors for fleet tracking, smart sensors that monitor system performance and
analytics that help machines self-diagnose issues.

The Internet of Things

The Internet of Things (IoT) is a network of objects or items that are connected to the internet
and are able to share data with each other. The Internet of Things can be used at home with
smart lighting and thermostats, in cars with sensors to promote safe driving, in the office with
connected alarms and in the industrial manufacturing space.
The shared, real-time data automation was once a manual process and extends throughout the
entire manufacturing process, from product design to gauging customer satisfaction. All of
this integration and digital technology creates smart factories and CNC machine shops, with
improved productivity and decreased downtime.
Standards For the IIOT on The Shop Floor
As you might have guessed, having so
many different smart devices on a shop
floor could create issues if not properly
addressed and regulated. That’s where
manufacturing standards and protocols
come in. These standards control how
CNC machines communicate and share
data with each other.
These technical standards define data tags
and behavior for software. Like other tech
regulations, they standardize and promote
interoperability between machines.
Simply put, it helps all of the machines at
your business work efficiently.
These manufacturing standards and protocols also enable you to effectively monitor cycle
time validation, error handling and machine utilization throughout your shop. You’ll have
visibility into all of your machines to boost overall efficiency.

The role of CNC machining in Industry 4.0 and how industry 4.0
affect CNC Machining
Industry 4.0 is changing how CNC machine shops run on a day-to-day basis. With all of the
smart technology and integrated software available, quicker turnaround times and decreased
downtime all result in increased productivity.
Data collection and analysis from sensors and other instruments help CNC shops test out new
products or study product use. Customer satisfaction is the main goal, and testing and refining
the product with data will only result in a better end product.
Industry 4.0 is only the latest in industrial revolutions. Data helps inform CNC machine shops
and manufacturers alike on how to make better products their customers will absolutely love.
It also allows business owners to examine their supply chain management process and
delegate dangerous or tedious tasks to the machines. Having all of these data points will
accelerate manufacturing and CNC machining as a whole.
While this type of automation can help prevent injury and increase your shop’s productivity,
these computer systems do still require operators to use them. You may also need to bring on
IT workers to help maintain these new systems.
Industry 4.0 technology is disrupting the manufacturing space. Bringing connectivity and
data collection to the forefront, the IIoT brings increases productivity and can lead to overall
higher customer satisfaction. Getting your CNC machine shop up to speed and implementing
these changes will require training, time and patience.
Training your current employees on these new systems and tools will help ease them into the
transition. These new computer-based systems require monitoring and will need to be
operated by a person, so educating and preparing your staff must be a priority as you embrace
this new digital transformation. Having all of your employees on the same page and trained
enough to properly use these new pieces of technology will help decrease downtime caused
by errors.

Machining Benefits from Industry 4.0

1. Persistent Operation
Traditional manufacturing techniques and machine tools are not always reliable. Downtime
increases costs, including production, labor, and maintenance costs. Industry 4.0 introduces
brand new opportunities in the form of preventive maintenance. With powerful performance
and real-time data streaming, maintenance personnel can better prepare for equipment
failures or errors. Budding problems can be detected and resolved early before routine
operations stop.
Big data solutions even make it possible to build predictive models and algorithms that can
be used to identify potential failure points, otherwise many failure points will be invisible to
the naked eye. All of this results in continuous operation of machines and equipment without
failures and higher efficiency than ever before.

2. Energy And Operational Savings

It is no secret that machine tools and hardware consume a lot of power. They are energy
hogs, even when they’re powered down and just in standby. With Industry 4.0 solutions, you
can better manage resource usage.
Incoming data collected by IoT sensors and platforms can be used to better inform
operations. Smart meters can be placed to effectively manage energy flow. The equipment
can be automated or appropriately powered to reduce the impact on the environment and
resources.

3. Real-time QA
Quality assurance is an important job in the manufacturing field, and has more to do with the
machines and equipment in use, which is beyond people’s imagination. When the equipment
fails, the efficiency drops or is completely inaccurate, the result will be the loss of the
product.
Therefore, manufacturers always have a quality assurance process to check products or
components for defects or minor errors. However, the problem with many of these processes
is that they cause production delays.
Industry 4.0 and related technologies will revolutionize this process through real-time QA
such as automated virtual metering (AVM) systems. Essentially, data about conditions,
quality, and status are collected and combined with information about machines and
processes. It provides a more complete overview of operations and provides real-time
elements for quality inspection.

4. Better human-machine interfaces

Improving the current version of machines and manufacturing equipment is not just about
performance and normal operation. The same applies to the communication standards of the
man-machine interface. Most workers will perform daily operations with robots and
machines (often called collaborative robots).
The future mechanical workshop or factory workshop will be very efficient, because people,
machines and robots can work side by side in a stable and safe environment. In order to
achieve this goal, a lot of improvements to the man-machine interface are needed.
Technicians will be able to remotely operate the equipment and send commands instantly.
The reporting system will provide real-time alerts and insights to operators, no matter where
they are.

Embrace Industry 4.0 In your CNC Machine factory

Industry 4.0 technology is destroying the manufacturing space. IIoT brings connectivity and
data collection to the forefront, thereby increasing productivity and improving overall
customer satisfaction. To make your CNC machine shop quickly adapt and implement these
changes will require training, time and patience.
Training existing employees on these new systems and tools will help them transition easily.
These new computer-based systems require monitoring and manual operation. Therefore,
when accepting this new digital transformation, education and training of employees must be
given priority. Put all employees on the same page and conduct adequate training to properly
use these new technologies.
Conclusion
Industry 4.0 is the latest wave of changes in manufacturing and commerce as a whole. The
integration of new technologies and the embrace of data can create more efficient processes
for manufacturers and CNC machining factories.
Industry 4.0 does not worry about this change because of the obsolescence of workers, but
brings new efficiency and improvement opportunities to existing processes. These new
machines still need staff to monitor and operate the system-in fact, you may need to hire an
IT team to resolve any software issues that arise. Industry 4.0 is an ongoing industrial
revolution. It is a revolution that CNC machining workshops can use to achieve and exceed
their goals.
In the age of Industry 4.0, your machine will be able to communicate seamlessly with
automation solutions and will continuously report its status. This applies to both the short-
term (“What am I producing now?”) and the long-term (“Which parts are showing signs of
wear?”). In short, the result is a highly streamlined, predictable and therefore more profitable
manufacturing process.
Industry 4.0 is the latest wave of change for manufacturing and commerce overall. The
integration of new technology and embracing of data can create much more efficient
processes for manufacturers and CNC machine shops alike. While the use of the IIoT
becomes more widespread, it’s up to shop owners to train their staff on this new technology.
Instead of fearing this change as the potential obsolescence of the worker, Industry 4.0 is an
opportunity to bring new efficiencies and improvements to already-existing processes. These
new machines still need workers to monitor and operate the system—in fact, you may need to
hire an IT team to help with any software issues that arise. Industry 4.0 is an industrial
revolution in progress and it’s one that CNC machine shops can use to meet and exceed their
goals.