It is somewhat ironic that software companies are promoting closer integration when an increasing number of toolmakers are separating design and manufacture by putting responsibility for CAM onto the shop floor. This approach gives a number of potential advantages.

First, shop floor operators generally know more about any quirks of the machines within their company. They should, therefore, be better able to select the optimum machining strategy, tool type and size, feedrates, stepover and stepdown, etc. for each job, taking full account of any limitations of the machine on which it will be run. This gives more efficient use of the CNC machines and also should ensure higher quality machining.

The shop floor personnel also will be more aware of new machining technology. Improvements in cutting tools are of particular importance since modern tooling allows the use of speeds and feeds that would have been impossible even five years ago. Failing to take advantage of these faster options could mean that significant opportunities to increase productivity are being missed.

Just as important, the machine operators will be more aware of conditions on the shop floor, in particular the tooling, materials, machines and accessories such as clamps, that are currently available. This will help to improve job scheduling and reduce downtime.

Similarly, the machine operator is able to make any changes to the program that might become necessary on the spot. For example, if the tool selected for the job is already being used, or becomes worn and cannot be replaced, the machine operator will be able to generate a replacement program for the nearest alternative tool size relatively quickly. The time saved will increase machine utilization.

The mold designers also will benefit because removing CAM programming from their workload will leave more time for design work and quoting new business. The latter factor is becoming especially important. The need for faster product development means that customers are not prepared to wait as long for quotes.