Modern Machine Shop is focused on all aspects of metalworking technology - Providing the new product technologies; process solutions; supplier listings; business management; networking; and event information that companies need to be competitive.
Issue link: https://mms.epubxp.com/i/850702
72 MMS August 2017 mmsonline.com FEATURE r e p o r t a s p i n d l e u t i l i z a t i o n o f 72 p e r c e n t compared to 60 percent for others, while using newer equipment, too. Average age for CNC machines at Top Shops and other shops is 7 and 10 years, respectively. Top Practice—Nearly 60 percent of Top Shops use tool presetters compared to only 36 percent of other shops. This is one example of shopfloor automation that doesn't involve a robot. Trend—There was a considerable increase in the percentage of Top Shops that use additive manufacturing/3D printing equipment. This year, 37 percent of them reported having this equip- ment compared to 19 percent in last year's survey. Virtually all of those shops use this capability for prototyping, but 74 percent of them also use it to 3D print tooling and fixturing for their own use on the shop floor. SHOPFLOOR PRACTICES This year, there was a significant increase in the number of Top Shops using enterprise resource planning (ERP) sof tware. In past sur veys, this percentage has ranged from 50 to 60 percent, but 83 percent of this year's Top Shops use it. This software offers a number of benefits, includ- ing estimating production time/cost, job schedul- ing, in-process job tracking, logging each step in a part's progress through the shop and offering historical view of resources used on prior jobs (which can be helpful in planning new work). The use of machine-tending robots among Top Shops had steadily increased over the first three years we offered the survey, but it has seemed to plateau in recent years. This year, 26 percent of those shops use robots. It will be interesting to see if collaborative robot technology, which enables robots and humans to safely work in the same area, will push this percentage higher. Key Per formance Indicator—Top Shops turn jobs faster than other shops. Their order lead time (receipt of order to order delivery) is 20 days compared to 25 days for other shops, and they report having a higher on-time delivery rate of 95 versus 90 percent. Top Practice—Many shops start their lean manufacturing journey by implementing 5S work- place organization tactics. This year, 54 percent of Top Shops cite using this practice compared to 46 percent of other shops. Those higher- performing shops also tend to implement other lean initiatives more so than the others, such as value-stream mapping and cellular manufacturing. Trend—In each of our seven surveys, a higher percentage of Top Shops reported having quality certifications, such as ISO, AS and NADCAP. This year was the highest report at 68 percent (com- pared to only 49 percent of other shops). That A whopping 83 percent of this year's Top Shops use enterprise resource planning software, the highest percentage since the survey was launched in 2011.