Cutting tool manufacturer secures Industry 4.0 accolade

Germany-headquartered cutting tool manufacturer Paul Horn GmbH has received a second Allianz Industrie 4.0 Award Baden-Württemberg, underlining the company’s continuous pursuit of innovation and its pioneering role in digitalisation.

To extend the service life of its inserts and solid-carbide tools, which must meet the highest standards of precision and quality, Horn offers customers a reconditioning service worldwide. Refurbishment takes place in fixed steps, regardless of actual wear. Previously it was not feasible to document individual measurements or other data on receipt of the tool and after processing.

Horn’s innovation has been to digitally map the lifecycle of tools to enable the recording of quality-critical data using a web-based solution customised for specific groups of tooling products. The Horn Service Platform (HSP) prevents errors and reduces lead-times by digitally automating and accelerating administrative tasks.

The way in which HSP is able to streamline the assessment of the initial condition of worn tools after receipt and maintain order data in an enterprise resource planning (ERP) system is the basis of the latest award.

More than 15 stations in Horn’s factory have been connected to the tool manufacturer’s Industry 4.0 digital production infrastructure, for which the company was awarded an Allianz Industry 4.0 Baden-Württemberg Award in 2023. The most important processes monitored include laser marking, grinding, various tests and measurements, cleaning, blasting, coating, packaging, and shipping.

The HSP digitally assigns a unique identification number to each tool manufactured, transcending the boundaries of a classic ERP system. For seamless traceability, data can be recorded throughout the servicing process and displayed on a web interface in a structured and transparent manner. It includes all quality-critical data, such as measured values (height, diameter, concentricity, etc), test reports, images and comments. Horn and its customers share one system, but with individual views and clear demarcation of the information.

The introduction of HSP has significantly speeded delivery of reconditioned tools and created transparency across the tool lifecycle. Additionally, whereas servicing was formerly only economical for large quantities of tools, now smaller batches may be processed cost-effectively. The data collected provides the basis for future analyses and optimisation of manufacturing processes.

Horn is gradually rolling out this digital solution and will use it in other product areas, with gear skiving tools and PCD tools expected to follow.