'Learn-as-you-go' reduces shop's 'time-to-part': making a profit by running one-offs and short production runs in a variety of materials from a range of suppliers frequently challenges shops to choose between manual or CNC machines to turn a profit. A Michigan shop discovered how to make the choice simple.At Prince Industries (Livonia, MI) a unique blend of prototype and production work keeps this 30,000 sq.-ft. job shop very busy. Its customers include a variety of tool and diemakers, aircraft component suppliers, heavy construction equipment builders, energy producers and steel foundries. The shop houses an assortment of milling, turning and grinding machinery of all types, from manual to full CNC (Computerized Numerical Control) See numerical control. CNC - Collaborative Networked Communication . A majority of the jobs here involve shaft, ID and chucker work, usually in print-to-prototype and small quantity runs. Predictably, the greatest challenge Prince Industries faces, according to according to prep. 1. As stated or indicated by; on the authority of: according to historians. 2. In keeping with: according to instructions. 3. owner Harold Eklund, is the programming and set-up time on the machines. Founded in 1978, this company has met this challenge in various ways, over the years. In general, the choice always came down to manual vs. CNC machine tools, depending on the anticipated workload and job quantity mixes. [ILLUSTRATION OMITTED] Approach Change Then, something happened to change that paradigm at Prince. Eklund saw the Haco TUR tur: see ibex. 630MN with a Siemens (Elk Grove Village Elk Grove Village, village (1990 pop. 33,429), Cook and Du Page counties, NE Ill., a suburb of Chicago; inc. 1956. With a population of c.100 at the time of its establishment on open farmland, the village has grown dramatically and steadily, largely because of its , IL) Sinumerik 810D CNC and Manual-Turn software onboard Refers to a chip or other hardware component that is directly attached to the printed circuit board (motherboard). Contrast with offboard. See inboard. from Toolmex Machinery (Schaumburg, IL). The proverbial pro·ver·bi·al adj. 1. Of the nature of a proverb. 2. Expressed in a proverb. 3. Widely referred to, as if the subject of a proverb; famous. light bulb went off when he discovered this machine had the ability to run not only in a manual mode, helpful when his operators needed to program from a print directly into the controller, but also the Manual-Turn software would allow a "learn as you go" function for his operators, especially those without extensive G-code knowledge. "This is the easiest control to program in our shop," explains Eklund. "Training new employees is especially easy, fast and simple. We don't need to use a computer for G-code programming, so we can get to a finished part much faster, without any loss of accuracy or part quality. By compressing com·press tr.v. com·pressed, com·press·ing, com·press·es 1. To press together: compressed her lips. 2. To make more compact by or as if by pressing. 3. that time function, we've improved our profitability on a lot more jobs. Personally, I also like the excellent threading control on the machine," Eklund observes. The First Part The first part on the turning center is done in a teach-in manual mode, then the CNC supports the elementary contours, stock removal mode and cycle modes of thread, cut, groove, undercut undercut, n 1. the portion of a tooth that lies between its height of contour and the gingivae, only if that portion is of less circumference than the height of contour. 2. , drill and thread repair. The machine offers a step chain programming function, "Easystep," which allows a simple assignment of graphic symbols to the graphic elements and block commands. Up to 50 undefined elements can be calculated through the onboard contour contour or contour line, line on a topographic map connecting points of equal elevation above or below mean sea level. It is thus a kind of isopleth, or line of equal quantity. calculator with contour handwheel. Online simulation is said to be faster with more reliable checking of parametric values. The Haco is capable of handling a 4,400 lb. (max.) workpiece Noun 1. workpiece - work consisting of a piece of metal being machined piece of work, work - a product produced or accomplished through the effort or activity or agency of a person or thing; "it is not regarded as one of his more memorable works"; "the symphony was between centers with a 25" swing and a 4.1" spindle spindle: see spinning. A rotating shaft in a disk drive. In a fixed disk, the platters are attached to the spindle. In a removable disk, the spindle remains in the drive. Laptops use spindle designations to indicate the number of built-in drives. bore with dual spindle nose. Equipped with high-precision brushless motors and drives, the machine provides Prince another distinct advantage. Namely, the machine's control panel moves along the entire length of the work bed. While it may seem a detail, this feature allows an operator complete access to the controls while inspecting even the largest workpiece. It's one more time saver and, as Eklund observes, "all these improvements make a big impact on our bottom line." Prince processes all types of materials on the machine, from various tool steels to aluminum and Waspalloy[R]. End uses for the parts produced here include anchor components for U.S. Navy vessels, ballscrews for military aircraft, forging dies, prototype tooling and massive, one-of-a-kind construction equipment sections. Used primarily for axis movement and spindle control on this manual turn lathe lathe (lāth), machine tool for holding and turning metal, wood, plastic, or other material against a cutting tool to form a cylindrical product or part. It also drills, bores, polishes, grinds, makes threads, and performs other operations. , the CNC onboard has been very reliable, according to Eklund. He related his only service problem to date, in this way, "We burned out a main board and called for service. Siemens discussed the problem with us over the phone to diagnose the situation, then they sent someone out from their Chicago office with the proper parts and our machine was up and running the very next day." Time-To-Part While no specific time-motion study has been done, Eklund estimates the use of this "learn as you go" progressive automation lathe has resulted in at least a 10% decrease in the time-to-part for many of the jobs at Prince Industries. He also observed the Siemens control and Manual-Turn software allowed him to keep his same skilled operators running the machine at the improved productivity level. [ILLUSTRATION OMITTED] Tom Kob kob: see marsh antelope. , division manager for Toolmex, echoes this idea. "This machine fills a void for companies such as Prince, who routinely run prototypes and short quantity jobs. The CNC here doesn't require knowledge of G-code programming and therefore a lot of very skilled manual machine operators can remain at work and get much more accomplished. The reduction in time-to-part is indeed substantial and the operator can progress into the CNC mode in stages. It's been a very successful machine for us, precisely because it makes such a noticeable difference for companies such as Prince." The Siemens Sinumerik 810D is a compact CNC for drilling, milling and turning applications and features full integration with the company's Simodrive 611 digital drive package. Siemens Machine Tool Business www.rsleads.com/604mn-208 or Circle 208 for more information |
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