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feature the cell. These pertain to modifications to the cell control software or its CAM programming system. For example, the basis for the cell's overall control is System 3R's Workshop Manager. This software is designed to coordinate the operation of an automated cell by queuing work according to schedule, tracking the whereabouts of every pallet, moving pallets to and from machining stations and so on. This system was modified by the supplier for RMM so that an operator can interrupt automated operation with a command from any machine's CNC. The CNC system on each machine also required modification to enable it to disengage and re-engage with the Workshop Manager interface. In practice, the operator usually picks a convenient stopping point, such as the completion of the current pallet, to switch modes. When switching to manual operation, the robot removes the current pallet and takes it to the storage carousel for holding. T h e ro b ot e i th e r retu r ns w i th th e pa l l et identified via RFID for custom work (usually on a magnetic chuck) or activates the interlock to enable the operator to open the machine doors. From that point, the operator runs the machine in the conventional manner as if it were standa l o n e u n i t o n t h e s h o p f l o o r. W h e n t h e custom work is completed, the cell technician transmits a return-to-automated-mode signal to re-engage control of the machine by the Workshop Manager system. Mr. Graham reports that the machines in the Delcam, call 877-335-2261 or visit delcam.com GF AgieCharmilles, call 800-282-1336 or visit us.gfac.com The Hermann Schmidt Co., call 860-289-3347 or visit hschmidt.com Makino, call 800-552-3288 or visit makino.com Mitsubishi EDM, call 630-616-5920 or visit mitsubishi-world.com Rexam Mold Manufacturing, call 847-541-7900 or visit rexam.com/mold System 3R USA Inc., call 847-439-4888 or visit system3r.com 82 MMS September 2013 mmsonline.com cell typically run offline in manual mode about 4 to 6 hours a day. They run unattended for 80 percent of the remaining hours, depending on jobs available in the work schedule. The goal for each machine is to have it engaged in a workpiece for at least 125 hours per week. "We consider that to be the most cutting time that is reasonably achievable, given that allowances have to be made for first-article inspection and 100-percent component verification," Mr. Graham explains. "Reaching this goal for each machine and CMM in the cell helps our customers benefit from reduced lead times, improved overall quality, and ultimately, lower mold costs." The MegaCell is "Mega sMarT" Although Rail 1 of the MegaCell is fully operational, not all of its features and capabilities are in place. RMM's Automation Engineering Team maintains a list of refinements and enhancements that are now nearing completion, under implementation or in development. "Rail 1 is a working laboratory that will help us make the MegaCell the most intelligent system for automating mold manufacturing," Mr. Graham proclaims. He is fond of saying that the MegaCell is "mega smart." Some of the action items for further improvement of Rail 1's capability include: • Job schedule look ahead that will enable the robot to move into position at a workstation in anticipation of a load or unload activity. This will eliminate production delays for robot travel time. • Provisions to enable customers to view jobs in progress remotely via a wireless video streaming to the Internet. Cell supervisors currently have remote video monitoring and remote production control. They can run the sub cell and check inprocess inspection reports from mobile devices at home. • Concurrent programming. This will be seamless with Delcam's PowerShape, PowerMill and PowerInspect. The concept is to create a "onestop" programming session, starting with a SolidWorks 3D CAD mold design. Before the programmer creates the tool path for a graphite electrode, he uses PowerShape to create the electrode model and associated EDM programs. He also tags "critical to function" dimensions. He then uses the model of the electrode to create the