Next Generation Shopfloor Programming

Next Generation Shopfloor Programming (NGSP)

Revolutionize On-Machine CNC Programming using Next Generation Shopfloor Programming

Machine shops often rely on manual programming, while skilled CNC programmers are difficult to find. They also need an easier way to bring CAD models, tool information, and machine data together. Programming directly at the machine today often relies on manual data entry and limited conversational cycles, which makes it difficult to keep programming times short and program quality consistent. ModuleWorks NGSP helps operators create machining programs directly at the CNC controller. It uses CAD models, machines, tool data, and simulation to guide the process and check the program before machining.

Major Challenges

Scarcity of Highly Experienced/Skilled CNC Programmers

Highly skilled CNC programmers with higher professional experience are moving towards retirement age. It is a big challenge to consolidate the deep knowledge of CNC programming which is limited to these highly experienced individuals. This makes the organization highly dependent upon them. The new generation in today’s digital era is reluctant to learn classical on-machine CNC programming. So, there is a scarcity of experienced skilled CNC programmers in the market.

Longer Time for CNC Programming and Longer Machining/Cycle Time

The manufacturing industry is growing at a fast pace and the demand for experienced, skilled CNC programmers is rising due to the complexity of products to be manufactured and the complexity of CNC machine tools. The learning curve for new CNC programmers is very steep, which results in longer programming times and, hence, longer overall machining times.

Inconsistency in Program Output and Quality

Depending upon the skill levels and professional experience of CNC programmers, they may follow different approaches to programming. In the absence of a structured step-by-step guided approach, this may result in inconsistent NC code output. This may lead to inconsistent quality of the parts produced.

Higher Risk of Loss of Productivity

Lack of skill level and hands-on professional experience of a CNC programmer can lead to incorrect NC code output which can cause gouges, collisions, and tool breakage, as well as air cutting on the machine tool during the manufacturing process. This may result in damage to the machine tool, down time, loss of productivity, and delayed delivery of the product to the end customer.

Solution Offered by ModuleWorks

ModuleWorks NGSP helps operators turn 3D CAD models into machining programs directly at the CNC controller. It uses guided programming, machine and tool data, and simulation to make programming easier and enable operators to check the program before machining.

For machine tool builders and CNC control manufacturers, NGSP is an add-on software solution that brings simple, modern shopfloor programming to their machines.

Key Features

Touch-Based Feature Detection

NGSP lets a CNC programmer select a feature through touch and review how it can be interpreted in different ways. This provides a step-by-step, guided approach to CNC programming through interactive selection and definition of features. Touch-based input makes the workflow easier and more intuitive, shortens the learning curve for new programmers, and improves overall operating speed.

Support for a Variety of Machining Capabilities

NGSP supports programming for 3-axis and 3+2-axis machining of suitable prismatic parts, including indexing the work setup to any required plane. Every toolpath calculated by it respects the defined fixture plane and maintains a safe distance around the job, helping keep the programming environment collision-free.

Automatic Selection of Tool and Built-In Machine Context

Based on the geometry of the feature and the type of machining operation, NGSP proposes the most suitable available tool and brings the machine’s own tooling and setup information into the workflow. When connected to a tool database, tool selection is automated depending on configuration, workflow, and integration scope, and operators review and confirm suggestions at every step. This reduces reliance on specialist memory and enables more operators to program with confidence.

Automatic Machining Direction and Feature Type Suggestion

Working from the feature selected by the operator, NGSP automatically suggests the most suitable machining direction and feature type, reducing the need for manual determination. Combined with human-assisted feature detection, this reduces the number of manual steps during programming and helps shorten overall programming time.

Stock-Aware Smart Machining

NGSP tracks the current in-process stock after each operation, so only the material left to cut gets processed, avoiding non-productive air cutting and optimizing the toolpath for certain applications. Similar machinable regions can be grouped into shared operation blocks, combining roughing and finishing steps with different tools where appropriate.

Built-In Simulation and Toolpath Verification

Skipping verification is where setup errors and costly mistakes occur. Every NGSP program is checked in the same workflow before it runs, catching problems early. It also simulates the toolpath and detects collisions during the machining process. Operators get a clear, validated result before they begin machining.