Substantial Time and Cost Savings in the Maintenance Management of Production Tools due to Holistic System Integration

The Manufacturing Execution System (MES) ZEISS GUARDUS and ZEISS Reverse Engineering work hand in hand

Ulm / Oberkochen, Deutschland | 14 October 2020 | ZEISS Industrial Metrology

The efficient interaction of ZEISS GUARDUS and ZEISS Reverse Engineering (ZRE) accelerates not only the processes and correction loops in tool maintenance and tool construction. The real-time knowledge of the MES regarding the quality state of the manufactured parts as well as the possible wear of the production tool offers the potential of organising the process between tool maintenance and production in an obviously more efficient way.

The software ZEISS Reverse Engineering is a performant tool for the so-called reverse engineering process. Moreover, it offers specialised functions for the quick and easy correction of injection mould tools. These functions are especially used in the pilot production as well as for the repair of already worn tools. It is exactly this area where it is very important to correct the tools as quickly as possible so that the series production of “good” parts can be started or continued. The correction is carried out within ZEISS Reverse Engineering with three real data records: the CAD model of the tool, the CAD model of the product and the measured real data (e.g. point clouds or polygon meshes) of the manufactured plastic part as well as the measured real data of the used or worn tool.

ZEISS Reverse Engineering enables quick and easy correction of injection mould tools. © ZEISS
The Manufacturing Execution System (MES) ZEISS GUARDUS and ZEISS Reverse Engineering work hand in hand

The result of the correction resulting from the algorithm and the user entries is an updated CAD model based on which the tool will be subsequently adjusted by eroding or milling, for example. The successful use of the software and adjustment of the tool enable a reduction of the correction loops by up to 50 per cent.

The ZEISS GUARDUS users can also increase the efficiency within this process. The foundation for this is the integrated database of the MES of all the quality and production relevant product and process data in real-time as well as information about the setting up of production facilities, that is, the attachment of adequate tools to the machine and its calibration to the planned manufacturing order. During the production, the MES collects all the data which are important for the maintenance intervals and further correction of the tool, such as the manufactured piece number, cycles as well as information about the end of the production order and the stripping down of the machine. The ‘last part’ of the production order is sent to the testing laboratory for approval. When measuring this ‘sample’, the person responsible for quality assurance checks not only the product characteristics defined in the customer order but also indicators which inform about the current wear of the tool. This concentrated expertise of the MES enables you to analyse the worn areas via a false-colour image within the ZEISS Reverse Engineering and to correct them, if necessary. The maintenance management subsequently decides without any effort to obtain more information whether rework is required or whether the following production order can still be manufactured without any quality deviations. Therefore, the loop between the product and tool as well as between construction and production is closed.

Photos you’ll find in the Media Center (search for „MES-ZRE”).

Press Contact

Bernd Balle
ZEISS Industrial Quality Solutions
Phone: +49 7364 20-8148
bernd .balle @zeiss .com

About ZEISS

ZEISS is an internationally leading technology enterprise operating in the fields of optics and optoelectronics. In the previous fiscal year, the ZEISS Group generated annual revenue totaling more than 6.4 billion euros in its four segments Semiconductor Manufacturing Technology, Industrial Quality & Research, Medical Technology and Consumer Markets (status: 30 September 2019).

For its customers, ZEISS develops, produces and distributes highly innovative solutions for industrial metrology and quality assurance, microscopy solutions for the life sciences and materials research, and medical technology solutions for diagnostics and treatment in ophthalmology and microsurgery. The name ZEISS is also synonymous with the world's leading lithography optics, which are used by the chip industry to manufacture semiconductor components. There is global demand for trendsetting ZEISS brand products such as eyeglass lenses, camera lenses and binoculars.

With a portfolio aligned with future growth areas like digitalization, healthcare and Smart Production and a strong brand, ZEISS is shaping the future of technology and constantly advancing the world of optics and related fields with its solutions. The company's significant, sustainable investments in research and development lay the foundation for the success and continued expansion of ZEISS' technology and market leadership.

With over 31,000 employees, ZEISS is active globally in almost 50 countries with around 60 sales and service companies, 30 production sites and 25 development sites. Founded in 1846 in Jena, the company is headquartered in Oberkochen, Germany. The Carl Zeiss Foundation, one of the largest foundations in Germany committed to the promotion of science, is the sole owner of the holding company, Carl Zeiss AG.

Further information at www.zeiss.com

ZEISS Industrial Quality Solutions

ZEISS Industrial Quality Solutions is a leading manufacturer of multidimensional metrology solutions. These include coordinate measuring machines, optical and multisensor systems, microscopy systems for industrial quality assurance as well as metrology software for the automotive, aircraft, mechanical engineering, plastics and medical technology industries. Innovative technologies such as 3D X-ray metrology for quality inspection round off the portfolio. In addition, ZEISS Industrial Quality Solutions offers a broad global spectrum of customer services with ZEISS Quality Excellence Centers close to its customers. The company is headquartered in Oberkochen. Production and development sites outside Germany are located in Minneapolis in the USA, Shanghai (China) and Bangalore (India). ZEISS Industrial Quality Solutions is part of the Industrial Quality & Research segment.

Press Contact

Bernd Balle
ZEISS Industrial Quality Solutions
Phone: +49 7364 20-8148
bernd .balle @zeiss .com

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ZEISS Reverse Engineering enables quick and easy correction of injection mould tools.
ZEISS Reverse Engineering enables quick and easy correction of injection mould tools.
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