1. TOOL MANAGEMENT INTRODUCTION

2. TM Project Introduction
Organization
TM Project I
Service Center

3. Structure of Technological Tool Management
Customer’s
Production Schedule
Logistics
Schedule
Purchase
Stock Management
Cost Allocation
Scrapping
Production
of Customer
Tool Stock
Tool Setter´s Room
Tool Board
Service Centre
Disassembly/ Valuation
Transition of used Tools
De-coating
Regrinding
Recoating
Modifications
Repair
Tool
Stock
Tool
Board
Transition of new Tools
Assembly/ Tool Setting
New Tools
Gühring Organisation
Process Optimisation
Customer´s internal
technological
Production Support
ABC-Analysis of Tooling Costs
Analysis of non- stable Processes
Action Plan
Monitoring of Actions and Results
Tool Optimisation
Application Engineers
R&D
Test Area
Customer’s Responsibility
Responsibility Gühring TM
Production Site Customer
Tool Flow
Information Flow e
Dr. Lang

4. Tasks of the TM Training of the Employees Tool Purchasing
TM Project Introduction
Tasks of the TM
Training of the Employees
Tool Purchasing
Stock Management
100% Incoming Inspection
Technical support of the customer
Tool optimizing
Cost optimizing
Reporting
Tool presetting/tool circulation
regrinding/recoating in the service center
Communication with the customer (e.g. tool wear cards/meetings etc.)

5. Training of the Employees
TM Project Introduction
Training of the Employees
 During starting up a new TM Project
Engineers get training from experienced German tooling engineer during start up of the TM project
Tool setters get training from experienced German tool setters during start up of the TM project
Tool Manager, Stock Keepers, Purchasers and Administrative Staff are trained by the Project Manager
It is always possible to get support from experienced trainers in Guehring Changzhou or in Guehring Germany. There are also experienced tooling engineers and tool setters in the TM projects in China which are available for supporting new projects

6. Training of the Employees
TM Project Introduction
Training of the Employees
 While the TM Project is running
Weekly trainings held by the Tool Manager. Mostly review of actual problems, solutions and work organization issues with the target of continuous improvement
Monthly trainings held by the Tool Manager and Project Manager.
Review of different actual issues
Special trainings held several times per year by German experts or by experts from Guehring Changzhou. Mostly training for special tools, e. g. PCD/CBN tools, taps, which tool is the best for a special application etc.

7. Training of the Employees
TM Project Introduction
Training of the Employees
 While the TM Project is running
Trainings in cooperation with technical schools are held several times per year. Exchange of theoretical and practical knowledge, possibility to select qualified and suitable future employees
Weekly safety trainings including review of actual safety issues

8. Tool Purchasing TM Software indicates when minimum stock is reached
TM Project Introduction
Tool Purchasing
TM Software indicates when minimum stock is reached
Stock Keepers monitor the tool status. If minimum stock is reached, stock keepers fill in a “pre-order-list” and pass it to the responsible tooling engineer
Pre-order-list is confirmed by tooling engineer and passed to purchaser
Purchaser is making inquiry (normally from at least 3 different suppliers for first time orders)
After getting the quotations purchaser is choosing the supplier
Purchaser is getting confirmation (signature) of tooling manager
Tools are ordered
Orders are updated and tracked in the TM Software

9. Stock Management Most of the tools are stored in a “Kardex” lift.
TM Project Introduction
Stock Management
Most of the tools are stored in a “Kardex” lift.
Stock management over Guehring TM Software.
The Kardex lift is controlled directly by the TM Software.
Each stock movement is recorded in the TM data base.
The costs for each withdrawal are allocated correctly.
TM-Software indicates when the minimum stock is reached. The minimum stock is set up according to tool life, production volume and delivery time.
Orders are tracked by the TM software.

10. Stock Management Assembled Tools Stock Spare Parts Stock
TM Project Introduction
Stock Management
Assembled Tools Stock
Spare Parts Stock
Assembled Tools Stock
Kardex Lift (Tool Stock)

11. TM Project Introduction
Incoming Inspection
100% of the incoming tools are inspected. Exception: tools reground in the service center. These tools get a 100% outgoing check and are delivered with the checking report.
Visual check and measuring of the tools.

12. TM Project Introduction
Incoming Inspection
Inspection drawing available for each tool. Checking criteria is clearly marked.
Measuring results for each tool are recorded in a inspection report.
Documentation of the incoming inspection by punch and signature of the inspector on the delivery note.
Inspection Drawing
Inspection Report
Delivery Note

13. Technical Support Tool Optimization Problem Feedback List:
TM Project Introduction
Technical Support
Tool Optimization
Problem Feedback List:
Each problem that appears during the shift is recorded by the Guehring engineers in a “problem feedback list”
Daily “problem review meeting” with Guehring’s and customer’s engineers
If possible immediate problem solving with settling of the root cause. If immediate solution not possible:
follow up in the “monthly working plan” (see next slide)

14. Technical Support Tool Optimization “Monthly Working Plan”:
TM Project Introduction
Technical Support
Tool Optimization
“Monthly Working Plan”:
Weekly review and follow up of the status of open issues
Support from Guehring Changzhou available at any time
Support from Guehring Germany available at any time
Communication with external suppliers and organization of their support if necessary

15. Technical Support Tool Optimization Tool Tests/Replacement of Tools:
TM Project Introduction
Technical Support
Tool Optimization
Tool Tests/Replacement of Tools:
Written agreements with suppliers
Get the customer’s written approval for the test
Conduct test according to the “Tool Test Process”
Test results are recorded and followed up in the “Tool Test List”
Results are reported to the customer
If the test results are positive, Guehring will apply for the replacement of the tools and the corresponding documents

16. Technical Support Cost Optimization “Top20 Tooling Cost List”:
TM Project Introduction
Technical Support
Cost Optimization
“Top20 Tooling Cost List”:
Tool Cost “Top20” are listed monthly
Tool Manager and engineers follow up the “Top20” list and make action plan for cost reduction
Planned and target oriented follow up of the action plans and monthly review

17. Technical Support Reporting (monthly): Tool Cost per Part
TM Project Introduction
Technical Support
Reporting (monthly):
Tool Cost per Part
Tool Cost Top20 and action plans
Stock Situation
Tool Consumption List
Abnormal Tooling Consumption

18. Technical Support Tool presetting & tool circulation
TM Project Introduction
Technical Support
Tool presetting & tool circulation
Tools are withdrawn from the stock
Tools are assembled and set up
Collect measuring data in the pre-setting machine. Print out two set-up data labels: one on the tool, one in the tool setter’s book.
Tool is sent to the assembled tools stock or directly to the production line
Tools are used in the production
After using the tool, the machine operator fills in the “tool wear card”
Tool and “tool wear card” are collected and sent back to the TM room. Wear data for each tool is recorded in the TM software’s database
Tools are inspected
According to the status tools are set up again or disassembled and cleaned
Worn out tools/inserts are replaced

19. Trolley for tool delivery, Tool wear card on used tool
TM Project Introduction
Technical Support
Trolley for tool delivery, Tool wear card on used tool
Trolley for tool delivery, Tool wear card on used tool
Tool Presetting
Tool Presetting
Above: set-up data label
Left: Wear Data Terminal: Input the wear data from the tool wear card
Crank Grinding Wheel Assembly

20. Regrinding & Recoating
TM Project Introduction
Regrinding & Recoating
 Example: Service Center set up in Liuzhou for the TM Project in SGMW
 Equipment:
Two 5-axis CNC grinding machines
One circular grinding machine
One coating machine Guehring BA170.

21. Regrinding & Recoating
TM Project Introduction
Regrinding & Recoating
Used tools are collected separately in the TM stock room after coming back from the production line
The tools are sent to the service center regularly
After receiving, QC is checking each tool’s status (some tools cannot be reground, e. g. the tool is already too short, diameter already too small etc.). Disqualified tools are sent back to TM for disposal, qualified tools are put into the service center’s stock
According to the quantity of used tools in stock and the requirement of the TM, a production plan is made and agreed between the TM and the service center
The tools are reground and recoated according to the production plan’s sequence. If there are any deviations TM is informed immediately
100% of the finished tools are inspected by QC
Tools are sent back to the TM

22. Regrinding & Recoating
TM Project Introduction
Regrinding & Recoating
Advantages of the service center:
 All carbide tools used in the TM project can be reground and recoated in the nearby service center.
Short delivery time
Direct and daily communication between service center and TM project
Direct influence on the production plan of the regrinding center, e. g. very urgent tools can be made immediately

23. Communication
TM Project Introduction
Communication with Production Line (operators & line leaders)
Daily “morning meeting” of Guehring tooling engineers with the customer’s machine operators and line leaders
Machine operators write down tool wear data for each tool on the “tool wear card”
Communication with the customer’s tooling engineers:
Daily “morning meeting” in Guehring’s TM office
Weekly meeting in TM office
TM Software and other important information accessible for customer
Communication with customer’s management:
Tool Test Applications
Tool Test Reports
Tool Changing Applications
Monthly reports
Monthly meeting

24. Honor from China Outsourcing Association