The issues relating to tool management are complex and pose obstacles in smooth functioning of flexible manufacturing systems (FMSs). Although a variety of problems have been identified and some of them partly solved, a systematic procedure for tool requirement planning (TRP) needs to be evolved. This paper deals with a simulation model SIWTOOL, developed to determine tool replacements due to tool failures during machining of a part, triggered by transcendence of any of the parameters, namely, tool life, wear, temperature rise and breakage. It also determines the quantity of tools to be planned for each part type considering volume flexibilities as well. The simulation results are verified with field data.
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