When exploring the actual status of machines—following the 4M method advocated in lean management—machines can be categorized into several states: standby, setup, machining, and abnormal downtime. Only during machining does the machine truly generate added value for customers, which is why improving Overall Equipment Effectiveness (OEE) is essential. The EX Series Die-Sinking EDM and EXD Series Micro Hole EDM machines from Sparkle were designed based on this very principle.
From the perspective of setup time, tasks such as program editing, mold calibration, and setting the relative positions of electrodes and tools must be manually performed by operators. These activities typically account for about 20% to 40% of the machine’s daily operation time. During this period, although operators are working hard, the machine itself is not yet creating added value — that happens only during the EDM process.
To address this issue, Sparkle has, over the past two to three years, integrated customers’ 3D software systems. Through the automatic recognition of 3D tool geometry features and their corresponding machining positions on molds, combined with customized post-processor design, the system can automatically interpret data and convert it into machining programs. This automation significantly reduces operator setup time and enhances overall production efficiency.
The electrode tools are automatically interpreted through 3D post-processing analysis and converted into corresponding edge-finding and calibration programs. This eliminates the need for operators to perform setup tasks directly at the machine, preventing programming errors and saving valuable labor time. Operators can instead focus on mold and product design or other production processes. This automation not only reduces manual setup time but also cuts the overall setup process to less than 5% of total preparation time.
From Taiwan’s aerospace automation supply chains to Europe’s automotive mold production lines, Sparkle has successfully replicated and upgraded its automated production systems for European clients. By integrating electrode machining centers and EDM machines, engineers can easily schedule two weeks’ worth of machining plans into the automated line. The machines can operate 24 hours continuously, producing molds while adhering to lean management principles. At the same time, machining centers manufacture the electrodes required for the molds, realizing a Just-In-Time (JIT) supply chain model.
The new generation of machines launched by Sparkle is designed to meet customers’ competitive demands through highly intuitive operation concepts. With a user interface designed for zero training and support for rapid system integration, the machines feature built-in APIs and post-processor compatibility to enhance EDM utilization rates and smart factory integration. These innovations allow for exceptional scalability, responsiveness to market trends, and sustained industrial competitiveness.
Source: Economic Daily News
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