Ideas from the NTMA Manufacturing Technology Team

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Using advances in MRP system to achieve better part flowFamily of Part CellsFlex CellsLean Concepts

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Max Operations on TableTool Probing for Breakage or WearRedundant Wear ToolsPart Probing for SizeMax Parts on TableLights Out Machining

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Indexers, 4 or 5 AxisMill-TurnsMax Operations on TableHard Mill / Hard TurningCycle time to Part ratio

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Mikron

Utilizing more powerful Simulation Software – CGTModular FixturingPhoto Library of Set-upsPart Probing5S Tools to Organize work areasTouch ProbingTool Pre-Setting

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Max Operations on TableMax Parts, Pallet ChangersRedundant ToolingPart ProbingTool Probing◦ Tool Life ManagementRoboticsInternet-Monitoring◦ Control◦ Video

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Vacuum ChucksMagnetic ChucksCryogenic ChucksTombstonesFlexible Clamping System

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Take time to match Tool Geometry and Coating Technology with Material and ProcessesUse your Tool Rep to Solve Issues

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Horizontal Milling Machines◦ Pros

Can machine all or most of part when using a tombstoneCan run higher volumeMost are 4 axisGravity removes chips

◦ ConsSmaller part size and weightMore expensive machineMore floor spaceMore complex to program

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Vertical Milling Machine◦ Pros

Larger and heavier part on tableFaster set up, easer to programCheaper machineTake less floor spaceMore machine options and sizes

◦ ConsReduced space for operationsMachining from only one side

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Dedicated Line – Machines working as one line. (Transfers, rotary transfers) Linear Line – One operation per machine In-Line Manufacturing – Multiple machines performing same operationsCellular Manufacturing - Each machine performing different operations cluster together

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Pros – Fastest, one tool per machine, least manpower, lights out

Cons – Not flexible, milling operations only, one machine down will shut-down line, complex setup

Horizontal, vertical milling

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Pros – JIT, Multi parts types, one machine down will not effect line, lights out, Horizontal or vertical mill, short runs or long runs, very flexible.

Cons – Fixed only, one piece flow.

Horizontal, vertical milling and vertical turning.

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Pros – More flexible, one machine down doesn’t stop production, easy machine replacement

Cons – Requires more manpower, no lights out

Horizontal, vertical milling and vertical turning.

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Pros – Multi mfg types, most flexible, smaller run sized, adjustable manpowerCons – More manpower, no lights out, smaller run sizesMost types of machines, many different types working together.

Future - Upgradeable to robotics

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Hard Milling◦ Reduces polishing◦ Reduces cycle timeNewer EDM Technology◦ Improves Surface Finishes, cycle time

on both Wire & Sinker ◦ Large spool on wire extends lights

outs.

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Wire EDMLaserWater JetPlasma Cutting

Use these machines to Reduce Machining Time.◦ Even a combination of the two

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Pros◦ Use EDM to reduce Machining Operations, on small parts.◦ Runs Unmanned & Lights Out◦ Reduces Machining Stresses◦ Great for Very Small Parts◦ Extremely Accurate

Cons◦ Slow process◦ Recast on older machines◦ Only Conductive materials

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Pros◦ Fast◦ Runs Unmanned & Lights Out◦ Great for large and thick parts◦ Any material

Cons◦ Messy◦ Waste removal issues◦ Not for great thin material◦ Not as accurate as Wire EDM◦ Surface finish issues on thicker material◦ Kerfing without 4 or 5th axis

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Pros◦ Fast◦ Runs Unmanned & Lights Out◦ Great for large parts◦ Can cut just about any material

Cons◦ More costly to operate◦ Fumes◦ Best when cutting thinner materials◦ Not as accurate as Wire EDM◦ Poor surface finish◦ Kerfing without 4 or 5th axis

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Pros◦ Fast◦ Great for large parts

Cons◦ Costly to operate◦ Fumes and dirty◦ Least accurate◦ Hardens surface◦ Kerfing without 4 or 5th axis◦ Only metals

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Purchase Pre-finished Blanks MIM Metal Injection MoldingCastings

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Fast Non-Contact VideoMicro CMMs / CellsPortable CMMsEmpower Your MachinistControllable FeaturesWireless Inspect ToolsBuild Quality into your process do not inspect quality into you process

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Subzero quenching reduces stress in parts and cutting toolsAdding Liquid Nitrogen Coolant to Hard Milling and Turning Processes Improves Speed, Surface Finish and Reduces StressNitrogen for Super-Cooling Molds reduces cycle time, improves molding out-putCryogenic Clamping

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Utilizing more of what’s in your controlMost only use 40% of the control’s capabilities◦ High Speed milling◦ Better Tool Wear Capabilities Review your purchase documents,

Are there features that are not known.Contact your Distributor

Ask for any control software updates.Have them list any inactivated feature that may be useful.

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Water JetChemicalElectro ChemicalExplosive Extrude HoneMagnetic TumblingOutsourcing

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Your company many not be able to justify incorporating new technology. Try Networking and/or Outsourcing to other companies or members, until you can justify your own purchase. Use NTMA Members First for outsourcing: www.ntma.sourceauthority.com

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Updating Equipment and Employee Skills Updating Industry Image:◦ From Machine Shop to Manufacturing Technology CenterUsing Healthier Vegetable Based oilsAdding Air Cleaners, ConditionersIncreasing the Lighting

Incorporate a 6S lean Housekeeping ProgramSort, Set-in-order, Shine, Standardize, Sustain, Safety

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Use your machine distributorsMentoringCross TrainingOnline ◦ Tooling U - www.toolingu.com◦ NIMS - www.nims-skills.org

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Finding future employees, we must get involved, with actives which can showcase our industry.

Bots IQ - www.battlebotsiq.comUS First - www.usfirst.orgCannon of Fredon - www.fredon.comVisit Schools, Student plant tours

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There is a lot of simple under utilized machining technology out there, use your resources to find it. Challenge your employees to find a way to increase productivity. Consult with other companies to achieve a solution; form local networks.Attend trade association (NTMA) functions and learn from your peers.

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Presented By The NTMA Technology Team

Eric Kurzhal, Allied Specialty Precision, Team LeaderTed Toth, Toth Technologies, Co-Team LeaderJeff Bennett, Bennett Tool & DieRichard Ditto, Fredon CorporationTom Raun, Iscar Metals Inc.Mark Weathers, Excaliber Precision MachiningRich Wheeler, ABA-PGT, Inc.Eric Wilhelm, KV Inc.Kevin King, NTMA Technology DirectorRoger Atkins, MIC Group, NTMA Executive Team

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(800) 248-6862www.ntma.org

48 chapters48 chapters1700 member companies1700 member companiesMembers employ from 2 to 600 Members employ from 2 to 600

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Education – Apprentice contest, NIMS, Bots IQGlobal Marketing – Yearly Purchasing FairGovernment Affairs – Yearly Legislative Conference in DC.Next Generation – Round-table and Speakers at all National Conferences.PJAM – Precision Jobs for American ManufacturingRobotics Team –Bots IQTechnology –Technology Conference every other year. ◦ Responsible for 39 presentations at IMTS Manufacturing Business and Technology Forum.

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Wage and Fringe BenefitsMarket Intelligence Business ConditionsBusiness & CustomerMonthly Record newsletter

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Discount Programs

Fed-X, Yellow, Staples, MSC, Grainger, Office Max, DHL

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