Peter Zelinski has been a writer and editor for Modern Machine Shop for more than a decade. One of the aspects of this work that he enjoys the most is visiting machining facilities to learn about the manufacturing technology, systems and strategies they have adopted, and the successes they’ve realized as a result. Pete earned his degree in mechanical engineering from the University of Cincinnati, and he first learned about machining by running and programming machine tools in a metalworking laboratory within GE Aircraft Engines. Follow Pete on Twitter at Z_Axis_MMS.
Paulson Training Programs provides training content and services for the plastics industry, but much of what it has to say in this knowledge center is relevant to CNC machining facilities as well. The company points out that there is a bias among manufacturers toward investing in machines rather than investing in employee training. Why? One reason is the possibility that the trained employee might leave. However, another reason is the fact that the ROI for new equipment purchases is much easier to calculate. The costs of not training are hard to see. However, as Paulson points out, the facility that is not paying for training is probably paying for the lack of training, because those costs are very real.
For example, how much income is lost by accepting inefficient production as normal? Or by frequently scrapping parts or making corrections because of recurring mistakes? Paulson created these charts to illustrate the cost of unnecessary cycle time, downtime and rejects (again, tailored to the plastics industry, but still relevant). These are the ongoing costs that an investment in training can overcome.
A typical industrial robot has a form and function suggestive of a human arm. Does that mean the robot gripper ought to work like human fingers or a human hand?
This video demonstrates an alternate concept for robot gripping. The “Versaball” from Empire Robotics uses the compression of granular material to achieve its gripping force. This demonstration of the gripper on a robot arm from Universal Robots illustrates the strength, precision and control of the grip, not to mention its versatility, by lifting and relocating objects including a weight, a brick and a light bulb.
When I visited Taylor Guitars to learn about its manufacturing process, one of the manufacturing technologies I encountered was vertical machining centers. While some of the VMCs at the company’s factory in El Cajon, California, produce metal tooling for in-house use, most of these machines are carving wood to sculpt the guitars. In this video, factory neck department manager Julie Gardiner talks about this machining center application. Also, company founder Bob Taylor describes the challenge of making a product out of wood. An organic workpiece material, wood is very different from metal, in part because the quality of the material available is gradually in decline.
I visited Taylor as part of a film shoot for a forthcoming Edge Factor documentary on music-industry manufacturing. Find updates about the progress of this project at edgefactor.com.
On that same trip, we also shot this video at DW Drums.
Mazak’s recent Midwest Technology Center Event at its Schaumburg, Illinois, tech center gave attendees access to about 22 different milling, turning and multitasking machine tools. It also showcased various ideas related to deploying those machines effectively. Some of this involved technology particular to Mazak but some also involved technology broadly available throughout the industry.
An example of the former is Mazak’s idea of the “levels” of multitasking. The company has gone beyond helping customers identify whether or not multitask machining (turning, milling, and drilling in a single setup on a single machine) makes sense for a given job, and now instead looks to identify the different applications that are suited to each of the five levels of multitasking machines. Signage at the event identified multitasking machine tools according to what level each machine represented.
Machines and machined parts were labeled according to the multitasking levels they represent.
Smooth Technology was also on display. This is the company’s term for its system of control unit, machine hardware, and programming and processing software that combined achieve both efficient machine motion and an efficient experience for the machine user. Various machines at the event were shown equipped with Smooth Technology—a reminder that the unseen engineering of the control system is liable to be just as great a factor in the effectiveness of the machine as the kind of hardware engineering that is more obviously visible at an open house event like this.
Another idea that was on display was the promise of leveraging MTConnect, the broad-industry standard for sharing machine tool data. Mazak has used the information available through MTConnect to improve machine utilization within its own production in Kentucky. A presentation at the event by company vice president of manufacturing Ben Schawe detailed this, while on the event floor, a real-time display showed the overall equipment effectiveness (OEE) in real-time for Kentucky production machine tools. On this display, the bars were not all green. Yellow and red bars also appeared, indicating where a machine has dipped into a low level of OEE for any of a number of possible reasons, perhaps routine or perhaps noteworthy, just like in any production shop. The point of the display was not to boast about Kentucky’s productivity, but instead to illustrate the kind of intelligence that is now possible in the pursuit of greater efficiency.
A prominent display also detailed the company’s new hybrid additive manufacturing machine—combining CNC machining with additive manufacturing. I spoke about additive manufacturing at this event. That presentation gave me the chance to ask the audience, “If, in addition to subtracting material, you are now free to add material within the same cycle, then how does this change your sense of how to make the part?”
The hybrid machine is so new for the company that it did not have one available to show at this event. The company says its National Technology Center in Florence, Kentucky, will soon receive the machine, and will soon begin to experiment with it in cooperation with customers.
The additive manufacturing demo part included Inconel features grown onto a steel turned part.
Machining is so important to DW Drums’ latest pedal design that machining is part of the product’s name. In this video, Rich Sikra, the company’s vice president of manufacturing, discusses the production of the Machined Direct Drive pedal, the advantages of having that production in-house, and how the company has saved cost by using extrusions instead of machining from rectangular blanks.
I visited DW Drums as part of a film shoot for a forthcoming Edge Factor documentary on music-industry manufacturing. Find updates about the progress of this project at edgefactor.com.