Reducing machine time, scrap rate with automation

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PraesiDM developed franchisable ESOP-owned factory models designed to make automation accessible and scalable in the defense industry.

Advanced manufacturing technology provider PraesiDM had a customer grappling with critical inefficiencies stemming from a lack of automation in key operational areas, including CAM post-processors, simulation, tool management, and on- machine metrology. These deficiencies resulted in prolonged machining cycle times, an alarming rate of scrapped parts, and heavy dependence on manual program adjustments – inflating production costs and severely compromising lead times. PraesiDM was able to deliver a comprehensive and tailored suite of advanced automation solutions seamlessly integrated within Siemens PLM Suite, specifically NX CAD/CAM.

The deployment included:

• NX CAM post-processors and G-code simulation packages for optimizing machining across the entire suite of machine tools
• AT3D CAPPS NC advanced on-machine metrology software that enhances manufacturing precision with real-time feedback to correct errors from part offsets, fixturing, tool wear, and thermal effects.
• Siemens Virtual NC Kernel (VNCK) enables highly precise G-code verification with 1:1 simulation, providing real-time cost analysis by comparing actual runtime to simulated time.
• TMGR, PraesiDM’s tool management system, is built for 3D tool libraries, ensuring accurate and efficient tooling management, seamless model deployment for precise simulation, and standardized feeds and speeds.

Given the complexity of the customer’s components, workflows, and data ecosystems, implementing this solution demanded a high level of collaboration. Throughout the course of nearly a year, PraesiDM worked with the customer to ensure comprehensive deployment and integration, overcoming technical and operational hurdles. PraesiDM prioritizes customer service, ensuring operators fully comprehend the implemented strategies and can efficiently manage their operations. This commitment includes extended on-site support, complimentary training sessions, and responsive, personalized assistance tailored to the customer’s needs.

The impact of PraesiDM’s integrated solution

• Machining cycle times reduced more than 20%, enabling faster production
• Throughput surged by 300%, significantly elevating the facility’s
• productivity Scrap rates, previously as high as 25%, were virtually eliminated, demonstrating unprecedented levels of precision and reliability with the help of on machine metrology
• Lights-out production and simulation-driven operations, allowing processes that once relied on operator input to run autonomously without the need for manual intervention.

These advancements redefined the company’s operational capabilities. The head of the customer’s organization described the results as game-changing, as PraesiDM discussed how the integrated solutions resolved immediate challenges and paved the way for scaling these innovations across their global manufacturing network.

PraesiDM has introduced franchisable factory models within an Employee Stock Ownership Plan (ESOP) framework, designed to democratize access to advanced manufacturing technologies. These scalable factories combine cutting-edge automation, precision tools, and data-driven processes, empowering employee-owners to deliver innovative solutions for defense and other critical industries. By aligning with Industry 4.0 standards, PraesiDM’s model enhances precision, efficiency, and scalability, creating opportunities for businesses and employees alike to thrive in a tech-driven manufacturing ecosystem.

PraesiDM’s processes connect digital design with physical production. Using Siemens NX CAM, the company creates and reuses tool paths efficiently, incorporating advanced fixture concepts and part logic.

This system allows for rapid adaptation to new parts and engineering change orders (ECOs), minimizing downtime and improving productivity. Siemens Motion Control digital twin technology ensures precise tool path validation and machine tool safety.

In production, PraesiDM uses ZOLLER Tool Management Solutions combined with TMGR for real-time tool inventory management and setup sheet updates, reducing setup times and enhancing efficiency. Siemens Adaptive Machining Control (ACM) optimizes cycle times, while AAT3D CAPPS NC on-machine metrology provides real-time feedback and automatic tool compensation. These systems maintain strict net-zero tolerances, minimize scrap, and ensure consistent quality during production.

PraesiDM specializes in subtractive mill-turn machining. The company’s also incorporating cold spray additive technology to support hybrid manufacturing, enabling advanced material deposition for part repair and complex component creation. This virtually eliminates the need for castings or custom billet material sizing, resulting in streamlined productions and reduced material waste.

The company’s data collection systems capture information at every stage of production, from programming to final output, enabling continuous optimization, rapid tool path updates, and seamless integration into existing workflows. By reusing data across production cycles, PraesiDM reduces redundancy, shortens lead times, and improves process accuracy. These systems integrate software, tools, and analytics to convert digital designs into high-quality physical components.

PraesiDM’s vertically integrated approach provides manufacturers with advanced tools and systems to enhance precision and streamline production while supporting scalability and automation.

PraesiDM
https://praesidm.com

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