Process ImprovementsProcess Improvements

Steve TaylorFMF Supervisor

VCN 40T SpindleVCN 40T Spindle• Deep Bore Process exceeded Deep Bore Process exceeded 1hr 10 min1hr 10 min..• Chip Control issues.Chip Control issues.• Machine load concerns for production demandsMachine load concerns for production demands..• Reduced cycle time by 81%. Reduced cycle time by 81%. • New cycle time New cycle time 22 min22 min• Changed program to optimize tooling.Changed program to optimize tooling.• Changed depth/cut and speed/feed ratio for better tool life and Changed depth/cut and speed/feed ratio for better tool life and

chip control.chip control.• Replaced Sandvik with SECO inserts.Replaced Sandvik with SECO inserts.

SECO - CNMG 432 TP1500SECO - CNMG 432 TP1500

SECO - 32.51 TP1500SECO - 32.51 TP1500

200/250 STD Headstock200/250 STD Headstock• Cycle time for bore application Cycle time for bore application 60min60min..• Manpower could not keep up with demand.Manpower could not keep up with demand.• High Level of reported MDR’sHigh Level of reported MDR’s• Reduced cycle time by 50%. New cycle Reduced cycle time by 50%. New cycle

30min30min• Additional manpower eliminated for current Additional manpower eliminated for current

machine schedule.machine schedule.• One and done conceptOne and done concept• Implemented SECO boring technology.Implemented SECO boring technology.

300/350 STD Headstock300/350 STD Headstock• Cycle time for Headstock application Cycle time for Headstock application

180min180min..• Manpower could not keep up with demand.Manpower could not keep up with demand.• High Level of reported MDR’sHigh Level of reported MDR’s• Reduced cycle time by 50%. New cycle Reduced cycle time by 50%. New cycle 90min90min• Additional manpower eliminated for current Additional manpower eliminated for current

machine schedule.machine schedule.• One and done conceptOne and done concept• Implemented SECO boring technology.Implemented SECO boring technology.

VCN Clamp CylinderVCN Clamp Cylinder• Cycle time Cycle time 1.8hrs1.8hrs• Long turn aroundLong turn around• High production partHigh production part

• Reduced cycle time by 50%.Reduced cycle time by 50%.• New cycle time New cycle time 50min50min..• Adjusted program to optimize current tooling.Adjusted program to optimize current tooling.• Implemented Ceramic technology from Sandvik.Implemented Ceramic technology from Sandvik.

200/250 Rotor Sleeve200/250 Rotor Sleeve• Cycle time Cycle time 1.2 hrs1.2 hrs• Undesirable tool lifeUndesirable tool life• Chip control issuesChip control issues• Man operation due to poor processMan operation due to poor process• Reduced cycle time by 50%. Reduced cycle time by 50%. • New cycle time New cycle time 40min40min..• Implemented SECO insert. Implemented SECO insert. CNMG 432 TP1500CNMG 432 TP1500• Changed cutting data to control chip breakage Changed cutting data to control chip breakage

and tool wear.and tool wear.

STD 200/400 TurretsSTD 200/400 Turrets

3.4

5.3

3

4.7

0

1

2

3

4

5

6

200 Std 400 Std

Old New

Old ProcessOld Process New ProcessNew Process

Cutter - RA245-152 Cutter - RA245-152 Insert - R245-18T6Insert - R245-18T6Speed - 750RPMSpeed - 750RPMFeed - .3Feed - .3

Cutter - RA365-101Cutter - RA365-101Insert - R365-1505Insert - R365-1505Speed - 4000RPMSpeed - 4000RPMFeed - 1.4Feed - 1.4

Old New

12% Reduction12% Reduction

Semi/Finish Tooling for HeadstockSemi/Finish Tooling for Headstock

0

0.5

1

1.5

2

2.5

3

Cycle Time

Old

New

Cutter - R220-100-63 Cutter - R220-100-63 Insert - TNGN 22 PCBNInsert - TNGN 22 PCBNSpeed - 6000RPMSpeed - 6000RPMFeed - .6 PER REVFeed - .6 PER REV

Cutter - R220.96-100 Cutter - R220.96-100 Insert - XNEX 080608TRInsert - XNEX 080608TRSpeed - 1000RPMSpeed - 1000RPMFeed - 1.0 PER REVFeed - 1.0 PER REV

CYCLE TIMECYCLE TIMEOLD - 2.35 HRSOLD - 2.35 HRSNEW - 1.4 HRSNEW - 1.4 HRS

48% REDUCTION48% REDUCTION

Semi-Finish

Finish

MU-8800

Cutter - R290-100-63 Cutter - R290-100-63 Insert - R290 -12 03 6090Insert - R290 -12 03 6090Speed - 1000RPMSpeed - 1000RPMFeed - 1.0 PER REVFeed - 1.0 PER REV

0

50

100

150

200

250

300

510 Head 400 Car 450 Head

Old

New23%

44% 40%