Thanks to ballbar testing with a Renishaw QC20-W, the Autodesk Technology Centers now have more confidence in their machine tools.
While there are many changes to adopt when moving to five-axis, they all compliment the overall goal of better parts through less operations. heavy cnc machining
A company that was once a consulting firm has become a successful micro-laser machine shop producing complex parts and features that most traditional CNC shops cannot machine.
Horizontal five-axis machines cut cycle times in half at ARCH Medical Solutions – Newtown. But its leadership gives equal credit to a surprising factor: the OEM’s service department.
The hybrid machine tool is an idea that continues to advance. Two important developments of recent years expand the possibilities for this platform.
This CNC enables EDMs to switch between G-code and an integrated CAM system to adapt to changing conditions and make lights-out manufacturing more attainable.
A study in repeatable and flexible workholding by one OEM for another.
Intech Athens’ inventory management system, which includes vertical lift modules from Kardex Remstar and tool management software from ZOLLER, has saved the company time, space and money.
To cut out laborious manual processes like hand-grinding, this briquette manufacturer revamped its machining and cutting tool arsenal for faster production.
Adopting PCD tooling has extended FT Precision’s tool life from days to months — and the test drill is still going strong.
Moving to five-axis machining enabled this shop to dramatically reduce setup time and increase lights-out capacity, but success relied on the right combination of workholding and automation.
Emuge-Franken received the award for its specialized tool based on the new Cera-Cut end mill design.
Global manufacturer Fictiv is rapidly expanding its use of data and artificial intelligence to help manufacturers wade through process variables and production strategies. With the release of a new AI platform for material selection, Fictive CEO Dave Evans talks about how the company is leveraging data to unlock creative problem solving for manufacturers.
Implementing ProShop has led to a massive process overhaul at Marzilli Machine. From 2020 to 2021, revenue increased 64% without capital investment.
Hexagon has rearranged its software portfolio into five process-based suites, which include software for every step in the workflow as well as a new program that connects everything, increasing automation and collaboration.
Napoleon Machine, a defense contractor that provides parts for the M1 Abrams tank, recently took advantage of a CAM feature that allowed the company to streamline its cutting strategies and program offline. Here’s how the shop cut cycle times nearly in half with its large-format five-axis machining operations.
Nick Pinkston is a serial entrepreneur in the manufacturing technology space whose startups include CloudFab, Plethora and Volition, an online marketplace that’s designed to make finding and buying off-the-shelf components easier.
The February issue dives into digital technologies that not only streamline production, but make a tangible difference in people’s lives.
Thanks to ballbar testing with a Renishaw QC20-W, the Autodesk Technology Centers now have more confidence in their machine tools.
Tool-toolholder-spindle-machine combinations each have a unique vibration response. We can measure the response by tap testing, but we can also model it.
Measuring surface finish at the point of manufacture is often done by the same machinist who is manufacturing the part. They need tools that meet test requirements and are easy to use.
This new partnership will enable the automation of manual gaging processes, helping manufacturers eliminate bottlenecks and improve productivity.
Gage fixtures are the key to accurate and repeatable measurements, so make sure there is no play at its joints.
The platforms enables customers to source new and pre-owned CMMs powered by Verisurf software.
AI will become a tool to increase productivity in the same way that robotics has.
Muratec’s technology has marked turning points in automation, helping customers enhance competitive efficiencies across diverse industries.
Consider what types of implementation your shop prefers when deciding between workpiece-handling and pallet-handling automation solutions.
This new partnership will enable the automation of manual gaging processes, helping manufacturers eliminate bottlenecks and improve productivity.
This CNC enables EDMs to switch between G-code and an integrated CAM system to adapt to changing conditions and make lights-out manufacturing more attainable.
The company has integrated a platform that enables comprehensive digital integration in industrial settings, enabling for the connection of multiple devices and extensive data collection.
Across a range of technical presentations aimed at small and mid-sized job shops, the first-ever Automated Shop Conference (TASC) offered insights into several automated technologies, implementation strategies, shopfloor training tips, and even the untapped power of automated coolant delivery.
Automation is no longer a luxury in manufacturing today – it’s a necessity. The Automated Shop Conference (TASC) will connect job shops with experts who offer advice and considerations for this process.
The Automated Shop Conference (TASC) will give shops of all sizes and production volumes key insights and practical guidance on how to implement automation.
Looking to automate your shop floor? The Automated Shop Conference (TASC) will connect shops with experts who can advise them through this transition.
Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.
Staying adaptable and leading through change for 95 years and counting, Modern Machine Shop celebrates its 95th Anniversary since its first publication in 1928.
The advance toward increasingly automated machining can be seen in the ways tooling, workholding, gaging and integration all support unattended production. This is the area of innovation I found most compelling at the recent International Manufacturing Technology Show.
The renewal of collaborations, partnerships and networking opportunities created a new level of excitement at IMTS 2022 for 86,307 registrants.
Manufacturing has a multi-talented bunch of people, but who knew so many were adept in the facial hair industry? Check out the best of the beards at IMTS!
This year’s show celebrates 10 years of co-location between IMTS and Hannover Messe.
Brent Donaldson of Modern Machine Shop sits down with Supertec's Don Staggenborg to discuss what the IMTS veterans brought to this year's show.
Meet NASA mission system engineer Mike Menzel and learn more about the James Webb Space Telescope at Mitsui Seiki USA’s booth (338700) in the South Hall from 11:00 a.m. to 11:45 a.m. on Thursday, September 15.
Global manufacturer Fictiv is rapidly expanding its use of data and artificial intelligence to help manufacturers wade through process variables and production strategies. With the release of a new AI platform for material selection, Fictive CEO Dave Evans talks about how the company is leveraging data to unlock creative problem solving for manufacturers.
While there are many changes to adopt when moving to five-axis, they all compliment the overall goal of better parts through less operations.
Moments of change shine a light on the priorities that have been consistent a long time, and on the worth we carry forward out of a rich past into the future.
The act of qualifying CNC programs is largely related to eliminating variations, which can be a daunting task when you consider how many things can change from one time a job is run to the next.
Measuring surface finish at the point of manufacture is often done by the same machinist who is manufacturing the part. They need tools that meet test requirements and are easy to use.
Consider what types of implementation your shop prefers when deciding between workpiece-handling and pallet-handling automation solutions.
Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.
Verifying parts is essential to documenting quality, and there are a few best practices that can make the quality control process more efficient.
Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.
Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.
Explore Tech-Max, a CNC machine shop that specializes in precision machining large and complex parts ranging from 10 in. to over 10 ft.
Rimeco Products, Inc. is a family owned CNC Machine Shop located outside of Cleveland, Ohio. Cleveland is known for manufacturing, with a lot of large OEM’s located in and around the city. Rimeco specializes in aerospace and defense products. Their experience, has led the to create in-house machining solutions to maximize efficiency.
In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.
The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.
The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.
When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.
Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.
So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?
The Top Shops 2024 survey for the metalworking market is now live, alongside a new homepage collecting the stories of past Honorees.
To combat the skilled labor shortage, this Top Shops honoree turned to partnerships and unique benefits to attract talented workers.
Doubling sales requires more than just robots. Pro Products’ staff works in tandem with robots, performing inspection and other value-added activities.
From cobots to machine monitoring, this Top Shop honoree shows that machining technology is about more than the machine tool.
Deciding to narrow down its jobs and customers was a turning point for 2023 Top Shops Business Strategies honoree Manda Machine that has led to improvements in the front office and on the shop floor.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.
Verifying parts is essential to documenting quality, and there are a few best practices that can make the quality control process more efficient.
Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.
Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.
Explore Tech-Max, a CNC machine shop that specializes in precision machining large and complex parts ranging from 10 in. to over 10 ft.
Jrlon, Inc. is recognized as a dependable source and leading supplier of plastic and specialty metal products. They are one of the premier PTFE processors in the United States. Jrlon's expertise also covers a wide range of other performance plastic materials and alloy steels for custom molding, machining, gear manufacturing, technical industrial coatings, welding, and sheet metal fabrication. Driven by innovative designers and engineers, Jrlon manufactures unique products vital to a wide variety of industries.
The manually actuated bkac spot facing tool is well suited for large boring mills and other open-air machines.
Anja Taylor brings 10 years of national and regional experience to the role, with a focus on automotive, aerospace, small parts machining and general engineering.
GDS’ µGrind workholding solution has been customized to suit the requirements of ANCA grinding machines and can be set up in minutes.
The ProShop Digital Ecosystem will be used as the inventory management and ERP system at Purdue University’s Industrial Engineering School.
Kuka.MixedReality software displays tools and interference geometries for early detection of potential hazards that can then be eliminated before a robot starts to work.
Lincoln Electric will 3D print large-scale propulsion components measuring almost 10 feet in diameter and weighing up to 20,000 pounds.
This two-part webinar series will explore various levels of AI automation available in today’s manufacturing software. HCL CAMWorks will explore technologies in CAD and CAM software – along with presentations of workflows that save time during both programming and machining processes. This series will focus on ways to improve delivery times by speeding up your part programming and decreasing part machining time. Agenda: Learn about technologies that allow you to decrease machining time and simultaneously increase tool life Watch a presentation of revolutionary toolpaths generated by CAMWorks VoluMill, VoluTurn, and Sandvik Coromant’s PrimeTurning See details on the time-savings experienced on a variety of machines
Are you ready to start your journey toward an AS9100 certification? Are you certified but looking for ways to streamline and reduce the cost of your current process? Then this webinar is for you. ProShop is committed to giving you winning strategies and expert insights to achieve unparalleled speed, cost efficiency and excellence in aerospace quality management. Whether you're on the brink of certification, just beginning your AS9100 compliance journey or are getting prepared for your recertification, this webinar is your roadmap to rewriting the standards of industry performance. Led by seasoned industry leaders and featuring a panel of shop owners who've seen game-changing success, this dynamic session will unveil actionable tactics, innovative approaches and best practices tailored to streamline your AS9100 process while upholding the highest standards of quality and compliance. Agenda: Learn the proven methodologies to accelerate AS9100 certification timelines without compromising on quality standards Discover cost-effective strategies to minimize expenses throughout the certification journey Explore practical techniques for maintaining a robust quality management system that enhances operational efficiency and customer satisfaction Gain insights from real-world case studies and success stories of organizations that have redefined excellence in AS9100 certification achievements Receive expert guidance on navigating common challenges and pitfalls in AS9100 compliance, empowering you to lead the charge toward setting new industry standards
This two-part webinar series will explore various levels of AI automation available in today’s manufacturing software. HCL CAMWorks will explore technologies in CAD and CAM software – along with presentations of workflows that save time during both programming and machining processes. This series will focus on ways to improve delivery times by speeding up your part programming and decreasing part machining time. Agenda: See how you can maintain the digital thread through fully integrated CAD/CAM software Watch a presentation of SolidWorks and SolidWorks CAM programming with intelligence based machining Learn about powerful application programming interfaces (APIs) that streamline programming Hear how other machine shops have experienced dramatic time-savings by implementing CAD/CAM AI automation
Manual data capture continues to plague manufacturers. This band-aid approach to data-driven manufacturing not only forces operators and other personnel to capture and compile data but also leads to delayed and inaccurate information. In this webinar, a leading medical device manufacturer, Orchid Orthopedic Solutions, will share their story of transitioning away from paper-based documentation to automated production monitoring. Get an inside look at how the Orchid team is automating data capture and leveraging advanced analytics to drive daily operations with MachineMetrics. Agenda: The negative impact of manual data collection efforts How a leading medical device manufacturer transitioned to paperless data collection The value of automated data collection and advanced analytics for daily operations
Understanding the CNC surface grinding world is important to manufacturing, as many applications require CNC capabilities. Whether using a straight wheel for flat grinding, a relief wheel for shoulder grinding or a formed wheel for profile grinding, Okamoto has the technology to support a vast variety of applications. Learn more about the CANC series and its potential to modernize your everyday grinding requirements. Agenda: Grinding and common obstacles Machine functions and capabilities How Okamoto addresses these obstacles
Cloud-Native CAM with Onshape uses parallel cloud computation, reducing calculation time for toolpath generation and machine visualizations. Onshape’s architecture provides advanced data management support such as versioning CAM strategies, storing a history of all CAM operations in one centralized location. Onshape’s CAM studio supports two-axis, three-axis, four-axis and simultaneous five-axis machining scenarios with a broad range of industry-proven, optimized strategies such as adaptive roughing, profiling and more.
The Women in Finishing (WiF) FORUM features a variety of professional development and industry related sessions geared toward women in our industry. Supplementing the general sessions is a finishing facility tour, networking and team building activities. Through unique programming, participants will learn new ways to deal with issues that impact effectiveness, maximize professional impact, build strategies for success, learn about the latest trends in industrials finishing, and much more. All women who have chosen or are pursuing a career in industrial finishing, from the finishing line to executive management, are invited and encouraged to attend the WiF FORUM. PROGRAMMING Networking Events: WiF hosts a number of networking events throughout the year enabling members to connect in a relaxed, social atmosphere. We host an annual Women in Finishing reception at FABTECH. WiF FORUM: The WiF FORUM is an annual conference that features a variety of professional development and industry related sessions geared toward women in our industry. Supplementing the general sessions is a facility tour, networking, and team building activities. 2024 WiF FORUM April 15 - 17, 2024 Orlando, FL The WiF FORUM is being held at the Drury Plaza Hotel Orlando Lake Buena Vista. Room Rate: $199. Hotel cut-off date is Friday, March 22, 2024. CLICK HERE to make your reservation. Reservations may also be made by calling 1-800-325-0720 and referring to your group number 10067311. Details coming soon! Check back for updates.
SUR/FIN is the primary conference and trade show dedicated specifically to the surface technology industry. It is where leading surface technology companies connect, collaborate and contribute. And because it is the only conference and trade show sponsored by the National Association for Surface Finishing (NASF)—representing the $28 billion finishing industry—it attracts noted business leaders and prominent thinkers to a forum where relevant issues are addressed and technologies presented. Join noted business leaders, visionary thinkers and the who’s who of the industry as we delve into the most pressing issues and explore the latest cutting-edge technologies. Immerse yourself in an atmosphere of networking opportunities, enriching education and unbeatable collegiality. 2024 Show Dates: Wednesday, June 5: 5:00 pm – 7:00 pm Thursday, June 6: 10:00 am – 5:00 pm Friday, June 7: 9:00 am – 3:00 pm
RAPID + TCT is returning to the west coast after a decade away! For more than 30 years, RAPID + TCT has defined the crucial role of additive manufacturing and empowered the establishment of an industry that continues to conceive, test, improve and manufacture new products at a faster, more cost-efficient pace. SME and Rapid News Publications have teamed up to produce the annual RAPID + TCT event, which takes place June 25-27 in Los Angeles, California. The event is for those who provide technology and for those who need to understand, explore and adopt 3D printing, additive manufacturing, 3D scanning, CAD/CAE, metrology and inspection technologies.
Debuting in 2010, the Parts Cleaning Conference is the leading and most trusted manufacturing and industrial parts cleaning forum focused solely on delivering quality technical information in the specialized field of machined parts cleansing. Providing guidance and training to understand the recognized sets of standards for industrial cleaning, every year the Conference showcases industry experts who present educational sessions on the latest and most pressing topics affecting manufacturing facilities today. Discover all that the 2022 Parts Cleaning Conference has to offer!
Laser powder bed fusion is the most widely used additive manufacturing method for metal part production, and electron beam melting is a closely related technology. For metalworking facilities contemplating a move into metal AM using technologies such as these, here is a road map for success. Speakers will cover materials, safety, part design, production workflow and differences between laser and electron beam metal powder bed fusion systems.
FABTECH 2024 will be held October 15-17, 2024, in Orlando, Florida, at the Orange County Convention Center. FABTECH provides a convenient ‘one-stop shop’ venue where you can meet with world-class suppliers, discover innovative solutions, and find the tools to improve productivity and increase profits. There is no better opportunity to network, share knowledge and explore the latest technology, all here in one place. Future U.S. Show Dates and Locations 2023 – September 11-14 at McCormick Place in Chicago, IL 2024 – October 15-17 at Orange County Convention Center in Orlando, FL 2025 – September 8-11 at McCormick Place in Chicago, IL 2026 – October 21-23 at Las Vegas Convention Center in Las Vegas, NV 2027 – September 13-16 at McCormick Place in Chicago, IL
While there are many changes to adopt when moving to five-axis, they all compliment the overall goal of better parts through less operations.
Consider what types of implementation your shop prefers when deciding between workpiece-handling and pallet-handling automation solutions.
When getting a grip on stainless steel, make sure you are very specific in how you talk about it and understand the pertinent information you need.
Consider these spindle attributes to make a choice that is balanced, usable and compliments your processes as best as possible.
While nearly all ER systems will have cross compatibility, they’ll have small differences across manufacturers that make their implementation at the shop level not as standard.
CMMs may provide simple efficiency gains, but if you look deeper, the machine unlocks more complex work for your shop.
From cobots to machine monitoring, this Top Shop honoree shows that machining technology is about more than the machine tool.
Founded in 1950 on Long Island, New York, Stock Drive Products / Sterling Instrument (SDP/SI) began as a contract manufacturer taking advantage of its close proximity to major defense contractors. Over time, the company expanded into the aerospace, medical device and industrial markets — natural fits for a company already used to achieving the highly precise tolerances and demanding standards of defense work.
Here we see workers at SDP/SI programming a cobot to attend a Haas 500SS. The cobot is designed to alter its movement speed when near humans, making it a safer alternative to a normal robot arm. Additionally, users can program the cobot by moving it with their hand and saving the position, making it simple for even inexperienced operators to program. Photo Credit: SDP/SI
In 2013 the company began a reorganization process and consolidated four manufacturing locations into a single facility in Hicksville, New York, in 2017. This led to numerous benefits and earned the company Top Shops honors for its HR practices in 2019. Four years later, Modern Machine Shop is proud to again honor this Top Shop — this time in the category of Machining Technology.
The Hicksville facility is a 96,000-square-foot building that contains 300 machine tools worked by 200 employees. According to SDP/SI President and CEO Robert Kufner, finding that kind of space on Long Island was worth the pain. “It wasn’t easy, let me tell you,” he says. “We consolidated four locations into this beautiful new building here.”
This move centralized operations while keeping the company close to its workforce. “The owners understand that its workforce is a tremendous source of value,” Kufner says. “We have a lot of highly skilled workers here. People with decades of seniority, like Sue.”
VP of Operations Sue Anderson began at the company just out of college, working as a production control clerk. After 40 years with the company, she knows every inch of the production floor.
“We have 300 machine tools,” she says. “It’s an even blend of milling and turning. That includes a lot of DMG MORI lathes, several with dual spindles, many able to gear cut on the machine. Most have a 3-inch capacity for the bar feeders, with one that has a 4.25-inch capacity.” On top of this, the company has nine Swiss-type lathes (seven Stars and two Citizens), rounding out its turning capabilities.
The lathes at SDP/SI are equipped with bar feeders and Rota-Racks from Royal Products. This simple combination is an effective automation solution for lights-out production of round parts, as it can keep a CNC turning center running for many hours. Photo Credit: SDP/SI
Most of the milling machines are also DMG MORIs, primarily vertical machining centers. Most are 4+1-axis machines capable of turning when necessary with proper fixturing. Additionally, there are two five-axis Haas mills. “We use the five-axis machines for more complicated aerospace housings,” Anderson says. “The Super Precision Mini Mill has been here forever and can hold 0.0002 inches all day.”
While the sheer volume of machine tools is impressive, the company is also constantly investing in more equipment. “We’re reinvesting $1 million to $1.5 million every year, rotating out the older equipment and bringing in more modern machines,” Kufner says. “And I’m always asking for more,” says Anderson.
One key area of investment is automation.
One of the primary ways SDP/SI keeps production levels high is through automation. “We have pick-and-place robots tending high-volume jobs,” says Kufner. “But one of the most cherished sets of automation is the FMB bar feeder paired with a Rota-Rack from Royal.” This simple combination keeps over 100 lathes producing parts consistently with minimal human intervention. “The FMB is just a beast,” he continues. “They withstand vibration. They’re not finicky. They’re just really good machines.”
“When we do the extra work to figure out how to not touch the part a second time, we can reduce the cost of the part by 25%.” – President and CEO Robert Kufner, SDP/SI
Automation is not just about moving the workpieces in and out of the machines, however. “Our whole concept has been doing everything we can in the envelope of the machine without taking it out,” Kufner says. This means deburring, gear cutting and numerous other secondary operations are performed in the same machine tool. By getting as much work done in a single setup as possible, the company can dramatically reduce setup time and human error.
This DMG MORI Wasino uses a standard robot-arm automation package supplied by DMG MORI. This machining cell, along with the company’s bar-fed lathes, has contributed to the 1,600-2,400 hours of unattended machining performed each month. Photo Credit: SDP/SI
Anderson had to implement numerous techniques for completing secondary processes in the machine envelope. “We added Weiler brushes and other types of honing and deburring equipment into most machine tools,” Anderson says. This has enabled them to remove both interior and exterior burrs on most parts. “Plus, the twin-spindle lathes mean we can reach the back of the part without touching it,” she adds. “When we do the extra work to figure out how to not touch the part a second time,” Kufner adds, “we can reduce the cost by 25%.”
With this automation, SDP/SI has seen excellent results with unattended machining. Most lights-out production occurs through bar feeders, in addition to a DMG MORI Wasino that performs lights-out drilling, tapping and reaming using an integrated robot arm as part of a standard Wasino automation package.
Together, these techniques enable the company to perform 1,600-2,400 hours of unattended machining per month, a massive cost saver and dramatic improvement on throughput. “Working lights-out is an important way for us to reduce cost and pass those savings on to customers,” Kufner says.
The company is also constantly investing in new approaches to automation, including cobots.
Recently, the company purchased a Universal Robots cobot to attend one of the Haas cells, as well as some nearby DMG MORI mills. The cobot is equipped with door-opening attachments and grippers to tend the machines, and it can be wheeled between the different cells as needed.
The choice of a cobot over a traditional robot came to a number of factors:
With these goals in mind, the company’s decision to go with cobots makes perfect sense. Compared to traditional robot arms, the cobots fit much easier into the niche these machining centers fill.
However, the company is investing in more than just automation. Lately, it has dipped its toes into machine monitoring.
This year, SDP/SI took some careful first steps into machine monitoring with a system from Scytec. “We recently installed it on one side of the shop just to test it out and work out the bugs,” Anderson says. “We’re currently monitoring 19 machines.” The goal of this test was to discover what tangible benefits they could derive from machine monitoring, if any.
Here we see the Scytec machine monitoring system in place in SDP/SI’s test cells. Since installing this system on 19 machines, the company has seen a 10-15% improvement in spindle utilization for those manufacturing cells. Photo Credit: SDP/SI
The company chose Scytec because of its responsive customer service. “They were on-site during the entire installation,” Kufner says. “Compared to others,” Anderson adds, “they gave us the data we wanted to see in the way we wanted to see it.”
And what were the results of this test?
“Our spindle time is up 10-15%,” Anderson says. According to her and Kufner, the majority of this improvement comes from the ways that access to data has smoothed communication between machine operators and management.
“It brings in front of everyone’s faces whether a machine is running or not running, and the operator has to identify why it’s not running,” Anderson says. “It can be hard for machinists to convey how often the machines are down from mechanical issues,” Kufner adds, “but now we get to tap into data from the machine to alleviate the stress from the operator.”
“Our spindle time is up 10-15%.” – VP of Operations Sue Anderson, SDP/SI
By making the data visible and making everyone accountable, the shop has hard numbers to point to when improvements need to be made. “It allows us to address the problems and makes us accountable to the operators,” Kufner says. “It’s not a tool to beat employees over the head with, but a way to improve things and make their lives easier.”
Fortunately, the company had already invested a great deal into improving communication. “Before the move to our current facility, there were six of seven siloed operating areas with centralized decision-making,” says Kufner. Employees felt unable to act on their own initiative and felt they did not have permission to approach problems creatively.
“We broke down those silos and communication barriers,” Kufner continues. “This created a culture of open communication and led to employees who felt empowered to have ideas and act on them, to invest in the success of the business.”
This attitude of cooperation has proven vital for the success of the machine monitoring program, and the company plans to expand it. “We plan on expanding machine monitoring to the rest of the shop floor starting the next fiscal year,” Anderson says. Thanks to the company’s success earning the trust of its employees, this investment is likely to pay off.
Modern Machine Shop took an exclusive behind-the-scenes tour of an Amish-owned machine shop, where advanced machining technologies work alongside old-world traditions.
Understanding grinding wheel fundamentals will help you choose the right wheel for the job.
By employing advanced high efficiency milling techniques for the entire machining routine, SolidCAM’s iMachining technology can drastically reduce cycle times while vastly improving tool life compared to traditional milling.
Turn-mills are a type of multitasking machine that can shorten cycle times and help facilitate lights-out machining for two common machining types.
Implementing ProShop has led to a massive process overhaul at Marzilli Machine. From 2020 to 2021, revenue increased 64% without capital investment.
Aerospace machining is a demanding and competitive sector of manufacturing, but this shop demonstrates five ways to find aerospace success.
Despite enhancements to manufacturing technology, there are still issues today that can cause programs to fail. These failures can cause lost time, scrapped parts, damaged machines and even injured operators.
boring machine process Modern Machine Shop is the leading publication and media brand in North America devoted to CNC machining. MMS combines unprecedented editorial access to manufacturing facilities with decades of experience to provide long-form content that is both insightful and impactful. Learn More