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Posted by Bill on January 8, 2010, 10:40 am
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> 8725-a4954327f922@r24g2000yqd.googlegroups.com:
> VDI - Very Dumb Idea
>
> So the best bet is to get the VDI out of the equation. I would look into
> replacing your VDI holders with a Quick change system like Kennametal KM
> or Sandvik Capto. The adapters stay on the turret and once dialed in the
> VDI part stay locked down and the quick change shanks repeat well.
>
> Next look into re-tooling with some multifunction tools. A multifunction
> tool can be different things. For example on a part that has five
> different bores in the ID, rather than using several drills and boring
> bars, you buy a step drill and step reamer taht will rough and finish
> all the bores with just two tools. It seems obvious, but fewer tools =
> less set up time. Nowadays these tools can all be insert tools too.
>
> Multifunction tools can also be tools that combine functions. For
> example Iscar makes a combination drill/boring bar/thread tool. So
> rather than setting three tools, you are setting one. These tools have
> the advantage of being an "off the shelf" item vs. form tools but you
> pay for that with slower cycle times.
>
> There are also combination turning boring bars, etc.
>
> When you look at re-tooling the turrets, it is also a good time to look
> at adapting high pressure coolant if you don't already have it. If you
> do have it, choose a quick change system with through coolant. That
> eliminates screwing around with plumbing when you use an insert or spade
> drill.
>
> If you run repeat work, in other words the same jobs over and over
> again, consider building special tool adapters that can hold multiple
> tools in one turret station and try to get as many if not all the tools
> you use mounted on the turrets. This is another area where multifunction
> tools can help. If you have this situation, you just change your
> workholding, call up the program and go.
>
> In any case, switching to quick change tooling should eliminate touching
> off tools. Now you will need different offset values for different nose
> radius tools, but just write to the geometry offset from the program.
> Set finishing offsets a little away so the part can be measured in
> place, and the finish tool re-run.
>
> Or consider in process gaging by adapting a probe. It is more involved
> initially to get the kinks worked out, but is a time saver on repeat
> work.
>
> Next look at your work holding. Since you are switching spindle liners,
> I'm wondering if you work strictly from bar, mostly from bar, or mostly
> chuck work with an occasional bar job. If it is strictly bar work, get a
> Microcentric quick change collet chuck. That will take your changeover
> time down to 30 seconds. Otherwise look at quick jaw change chucks,
> collet pad adapter jaws, etc. If you have a quick jaw change chuck and
> two sets of master jaws for collet pads, you can internalize the collet
> pad changeover when switching to a bar job.
>
> The rest of your changeover time savings can be had by internalizing set
> up tasks. Things like mounting a drill in a drill chuck while the last
> job is still running. Set up your gages for the next part, etc. Also
> organize your work area so that all movement required during changeover
> is minimized. Use shadow boards and/or magnetic bars to hold hand tools
> right where you need them.
>
> An example would be if you need a 5mm hex key to loosen the lock screws
> that hold the spinlde liners in the spindle. And you also need a 5mm hex
> key for a tool holder in the tool zone. Then you should have two of
> them. One mounted by the back of the spindle and one mounted by the tool
> zone.
>
> Clean the area, get rid of clutter, don't store stuff in drawers, etc.
> 5S sort of things.
>
> You can also set up a video camera and tape a few changeovers. Study the
> tapes to see where you can eliminate movement by rearanging your work
> area. See where you waste a lot of time and focus on improving the big
> time wasters first. Then refine until you get where you want to be. Most
> turning machines can be changed over in 0-20 minutes. In your case I
> would shoot for ten minutes. But work toward it in steps. It looks like
> you need on average 2-1/2 hours. Try cutting that in half as your first
> goal. Then half again.
>
> Your boss might be reluctant to spend money on big ticket items like new
> work holding and quick change tool systems at first. So do the 5S thing
> first, show him the savings, then make the case for money to make
> further improvements.
>
> --
>
> Dan
All good ideas Dan. I see your religion is "Continuous Improvement" too.
Another aspect in set up reduction is creative planning. Smoothly
transitioning from similar parts to similar parts is more efficient than
dramatic transitioning from extreme to extreme. Although your goal is still
to be less than 20 minutes for the most extreme transition. Having one job
evolve into the next i.e. big to small, complex to simple, many features to
few features etc. is much more efficient than hopping all over randomly.
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> VDI - Very Dumb Idea
>
> So the best bet is to get the VDI out of the equation. I would look into
> replacing your VDI holders with a Quick change system like Kennametal KM
> or Sandvik Capto. The adapters stay on the turret and once dialed in the
> VDI part stay locked down and the quick change shanks repeat well.
>
> Next look into re-tooling with some multifunction tools. A multifunction
> tool can be different things. For example on a part that has five
> different bores in the ID, rather than using several drills and boring
> bars, you buy a step drill and step reamer taht will rough and finish
> all the bores with just two tools. It seems obvious, but fewer tools =
> less set up time. Nowadays these tools can all be insert tools too.
>
> Multifunction tools can also be tools that combine functions. For
> example Iscar makes a combination drill/boring bar/thread tool. So
> rather than setting three tools, you are setting one. These tools have
> the advantage of being an "off the shelf" item vs. form tools but you
> pay for that with slower cycle times.
>
> There are also combination turning boring bars, etc.
>
> When you look at re-tooling the turrets, it is also a good time to look
> at adapting high pressure coolant if you don't already have it. If you
> do have it, choose a quick change system with through coolant. That
> eliminates screwing around with plumbing when you use an insert or spade
> drill.
>
> If you run repeat work, in other words the same jobs over and over
> again, consider building special tool adapters that can hold multiple
> tools in one turret station and try to get as many if not all the tools
> you use mounted on the turrets. This is another area where multifunction
> tools can help. If you have this situation, you just change your
> workholding, call up the program and go.
>
> In any case, switching to quick change tooling should eliminate touching
> off tools. Now you will need different offset values for different nose
> radius tools, but just write to the geometry offset from the program.
> Set finishing offsets a little away so the part can be measured in
> place, and the finish tool re-run.
>
> Or consider in process gaging by adapting a probe. It is more involved
> initially to get the kinks worked out, but is a time saver on repeat
> work.
>
> Next look at your work holding. Since you are switching spindle liners,
> I'm wondering if you work strictly from bar, mostly from bar, or mostly
> chuck work with an occasional bar job. If it is strictly bar work, get a
> Microcentric quick change collet chuck. That will take your changeover
> time down to 30 seconds. Otherwise look at quick jaw change chucks,
> collet pad adapter jaws, etc. If you have a quick jaw change chuck and
> two sets of master jaws for collet pads, you can internalize the collet
> pad changeover when switching to a bar job.
>
> The rest of your changeover time savings can be had by internalizing set
> up tasks. Things like mounting a drill in a drill chuck while the last
> job is still running. Set up your gages for the next part, etc. Also
> organize your work area so that all movement required during changeover
> is minimized. Use shadow boards and/or magnetic bars to hold hand tools
> right where you need them.
>
> An example would be if you need a 5mm hex key to loosen the lock screws
> that hold the spinlde liners in the spindle. And you also need a 5mm hex
> key for a tool holder in the tool zone. Then you should have two of
> them. One mounted by the back of the spindle and one mounted by the tool
> zone.
>
> Clean the area, get rid of clutter, don't store stuff in drawers, etc.
> 5S sort of things.
>
> You can also set up a video camera and tape a few changeovers. Study the
> tapes to see where you can eliminate movement by rearanging your work
> area. See where you waste a lot of time and focus on improving the big
> time wasters first. Then refine until you get where you want to be. Most
> turning machines can be changed over in 0-20 minutes. In your case I
> would shoot for ten minutes. But work toward it in steps. It looks like
> you need on average 2-1/2 hours. Try cutting that in half as your first
> goal. Then half again.
>
> Your boss might be reluctant to spend money on big ticket items like new
> work holding and quick change tool systems at first. So do the 5S thing
> first, show him the savings, then make the case for money to make
> further improvements.
>
> --
>
> Dan