I saw some pretty impressive things at IMTS last fall also. Most any machine can pick up part zero and tool length offsets and even measure the finished part, make adjustments and spit out a QC report. Even robotic arms to load and unload parts.
But it all cost money, big money.
Which is probable why what you saw 15 years is not more widespread. Curious of make and model and application.
The current trend is a pallet pool as far as milling goes. You have a drum with up to 300 tools, gobs of work offsets and TLO's even a AGV to transfer the tombstones.But you are looking at close to a million dollars, just to get it to this point. You still need someone to make the fixtures and set it up. Unless you plan on wasting a good deal of material, there is no one size fits all method to get around these things.
The software that supports the Cam end has done nothing but improve.. feature reconigition. in 3d solids, associativity with the model, ProE ,UG . There really is no excuse for waiting for programming to get the NC files out. Not anymore. With High Speed Machining, cycle times have dropped as well.
Setup time is dead time, no product is going out the door. If you can't push enough parts through to offset that lost time you won't make money. A big problem has been to stop running one thing to go over to another. Very rarely with something new is it just load and go to town, you have to grab that holder that you were just using and use it on the new part or disturb another setup, you might get lucky every once in awhile.
What causes a good deal of this is that by the time something hits the floor it is already late. Panic.. throw out the OT...put out the fire. Until the next time it happens again.
The improvement in the process, beside shooting the schedulers lends itself to reducing the design time so that manufacturing doesn't have to continue to tear stuff down to catch up. The bottleneck in most place is not having the part program it's having the model.
The advance in Cad needs to be in a intuitive package, input your needed parameters for what you desire. It looks to a database and offers choices. You have a library of parts that you can use, internal or web based vendors. If there is nothing that fills that need then you take it from there. Sure there won't be one size fit all there either. But in regards to software itself, this would cost a whole lot less than buying the next gen of machine tools. A company that just dropped a big chunck of change on a machine is not looking to do it again any time soon.
Quite frankly, it is going to be the Chinese that will be driving the machine tool market, sales will dictate what changes happen and with a cheap labor force they will be using people not robots.
I'm not slamming designers or anything like that. I am just stating what I feel based on what I have seen in the past few years. We have to sharpen our pencils because it slipping away real fast.. the aftermarket Harley fad is going to die out soon and we need to hold on to aerospace real tight.... sorry for being so long-winded
