Modern Machine Shop

NOV 2018

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.

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Page 106 of 155

MODERN MACHINE SHOP 105 BETTER PRODUCTION Getting In-Depth Help from Supplier According to Mr. Alexandersson, the objectives of the PIP were to increase equipment effective- ness, reduce scrap and improve tool life, but he admits to some initial skepticism. "To be honest, I figured it would end up being a big sales pitch, so we were all pleasantly surprised to see the depth of Sandvik Coromant's analyses and recommenda- tions," he says. "They looked at everything." Sandvik Coromant sales engineer Curtis Scott notes that, unlike a typical PIP, in which a Sand- vik representative goes onsite for a day or two to work with customers of all sizes to improve a specific problem, this one leveraged lean method- ologies to analyze multiple areas of the produc- tion f loor. "It was like a PIP on steroids," he says. "Aside from the machining process, we looked at material f low, safety concerns, how the machines and supporting equipment were arranged, the steps the operators went through during their daily work. It was a little bit of everything." It might go without saying that Volvo is no newcomer to lean manufacturing. However, it was not a lack of lean manufacturing knowledge that brought the two companies together, but rather the desire for a fresh set of eyes. Increasing Throughput on the Horizontal Machining Cell Together with designated Volvo employees, Sand- vik Coromant engineers split into two teams. Those assigned to the horizontal machining cell found that the machine tools and fixtures were easily up to the task of machining the 4140 steel carrier housings assigned to them, but recom- mended replacing a number of the milling cutters. For example, a special-order slotting cutter's symmetrical design was causing deflection and the need for increased maintenance to the machine spindle. By switching to a standard CoroMill 331 slotting cutter, process security and part quality were improved while machine loads were light- ened, reducing maintenance concerns. Another special form tool, a 12-insert cutter with a nine- to 12-week lead time was replaced with a CoroMill 390 90-degree shell mill and a CoroMill 495 chamfering cutter, through which cycle times were reduced from 2.87 minutes to just 1.75 minutes. Similar results were achieved with a 4-inch-di- ameter CoroMill 745 face mill, which cut cycle time in half to just 1.34 minutes, reduced the Quick Change Collet Chucks MicroCentric introduced Quick Change Collet Chucks to North America in 1986. We offer Dead Length and Pull Back designs for Bar and Chucking applications up to 160mm (6.3") capacity. Increased Flexibility and Productivity Change Chucks

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