Industry Asia Pacific 18

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Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

FLUKE PROCESS INSTRUMENTS MONITOR THE MINI WAVE

5 STEUTE NEW SERIES OF EX POSITION SWITCHES FOR TEMPERATURES DOWN TO -60°C

6 SECO TOOLS TEN SIMPLE STEPS TO PEAK PERFORMANCE AND PRODUCTIVITY

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FEINTOOL NEW XFT 2500SPEED FOR HIGHEST FINEBLANKING REQUIREMENTS

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18 | Industry Asia Pacific | January 2017

THE INDUSTRY MAGAZINE FOR ASIA

FLUKE PROCESS INSTRUMENTS

FLUKE PROCESS INSTRUMENTS

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STEUTE

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NORD

FEINTOOL

BALLUFF

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HMS INDUSTRIAL NETWORKS

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ESPRIT

NORD

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SECO TOOLS

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ADVERTISERS: MEPAX 21

www.industry-asia-pacific.com

Contact: Long WEI Editor in Chief: editor@industry-asia-pacific.com Send your press releases to: editor@industry-asia-pacific.com To receive Industry Asia Pacific magazine free of charge, please subscribe online at www.industry-asia-pacific.com Industry Asia Pacific is the English-language magazine for engineers, published by IPM (Industrial Portal Media) It contains the latest product and company news for industrial markets.

Industry Asia Pacific edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used.

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NEWS

COMPACT LOGGER CHECKS CURE OF COATED MONOBLOCK CONTAINERS

The new, highly precise miniature logger records detailed temperature profiles of monoblock processes.

Fluke Process Instruments has developed a miniature monitoring solution for monoblock cure processes.

The DATAPAQ MonoPaq2 system profiles the metal temperature of coated aluminum bottles, aerosols, and collapsible tubes both in IBO and OBO lines.

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he thermal barrier measures merely 41 x 48 x 195 mm, making it 43% smaller by volume than the preceding generation. The temperature profiling system can be used in lines with very closely spaced pins (>45 mm) and with various product basket sizes. This engineering success is primarily based on the development of a new data logger with a minimal footprint. The new DATAPAQ MicroQ18 logger connects four thermocouples via micro-miniature sockets and logs up to 32,000 readings per channel with an adjustable interval of 0.05 s or more. Its accuracy of ±0.5 °C puts it squarely in the class of the best available loggers.

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Downloaded to a PC or notebook, the thermal profile can be reviewed with the DATAPAQ Insight software, which includes versatile visualization, analysis, and reporting functions.

Manufacturers can thereby optimize their oven settings and ensure that every product experiences the specified time at temperature. Regular monitoring is facilitated by the compact size and light weight of the system. Mounting brackets are available in different versions for quick and secure attachment in any line layout. www.flukeprocessinstruments.com

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MONITOR THE MINI WAVE

The new DATAPAQ SelectivePaq is a complete solution for monitoring the stability and repeatability of miniature wave selective soldering processes.

Fluke Process Instruments announces the smallest thermal profiling system designed specifically for miniature wave selective soldering processes. The DATAPAQ SelectivePaq uses four thermocouples to take measurements from the electronic assembly as it passes through the preheating and dip soldering phases. Sample intervals can be adjusted to up to 20 times per second.

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he detailed temperature profiles enable electronics manufacturers to adjust their operations for optimum efficiency, validate the consistent quality of PCBs to customers, and prove adherence to both solder and component temperature constraints. The profiling system combines a new four-channel DATAPAQ MicroQ18 data logger with the latest micro-miniature thermocouple plugs and a low-mass thermal shield merely 20 mm high and 40 mm wide. It is therefore optimally suited to monitor the performance of machines that offer very restricted space and for use with holding frames. The complementary DATAPAQ Selective Soldering Process Sensor Array facilitates regular and frequent process stability measurements.

The logger provides a superior accuracy of ±0.5 °C and resolution of 0.1 °C. It connects up to three height-adjustable wave contact thermocouples and up to two preheat thermocouples for monitoring both process phases. The preheat thermocouples contain a top and a bottom sensor and are designed to work with IR and convection preheat technologies. The machined-from-solid aluminum logger case and user-replaceable rechargeable battery pack ensure a long operational life and lowest ownership costs.

The system is supplied with the full DATAPAQ Insight Reflow software. Data analysis includes maximum slopes, maximum temperatures, and wave contact times. The software enables data export to other Windows-compatible programs.

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www.flukeprocessinstruments.com

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FOR TEMPERATURES DOWN TO -60°C Explosion-protected, robust and resistant to cold: new series of Ex position switches.

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ffshore industry knows no fewer than four factors which make extreme demands on switchgear.

There is a risk of explosions; switches are exposed to high levels of mechanical wear and tear; the environment is corrosive; and it can be very cold.

The steute business unit “Extreme” has developed the position switches in its Ex 97 series for precisely this requirement profile – and will be presenting them at the SPS IPC Drives.

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These position switches, with dimensions to DIN EN 50047, have been tested and approved according to ATEX and IECEx for use in gas Ex zones 1 and 2, as well as dust Ex zones 21 and 22. They can be used in temperatures as low as -60°C, which is very demanding on housing construction and sealing. For example, it must be guaranteed that the switchgear's high protection class (IP 66) will be maintained in these subzero conditions at all times, even after a 7-Joule impact test.

For this reason, the stable housing is manufactured from high-quality fibreglass-reinforced plastic. The sealing of the housing cover is completely vulcanised, while the sealing of the plunger features a redundant sealing system, comprising an external sealing cuff able to withstand low temperatures and an internal Teflon sealing ring.

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The sealing materials have been cleared by their manufacturers for temperatures down to -95°C, and the lubricants down to -75°C. There is therefore a sufficient “tolerance” to the steute-approved temperature of -60°C. This gives users the certainty that the new position switches will work reliably even in truly extreme ambient conditions.

Due to a comprehensive range of actuators (plunger, roller plunger, roller lever, parallel lever, turning lever, adjustable turning lever, push button…) and their compact dimensions, the Ex norm switches are very versatile and easy to integrate in a surrounding construction. They are available with slowaction or snap-action and, as an added bonus, earthing and potential equalisation are superfluous because of the protection-insulated plastic.

This set of features in the Ex 97 series makes it a good example of the “Extreme” switchgear developed by steute.

It is suited not only to applications in the chemicals industry and energy technology, but also e.g. for position monitoring of flaps and valves in plants of the oil and gas industry (offshore and onshore), as well as on ships travelling through the Arctic. www.steute.co.uk

NEWS

THRIVING IN INDIA Jutta Humbert lights an oil lamp during the opening ceremony of the service area in October 2016 (also pictured, from the left: Ashok Tanna, Managing Director at Linnhoff Pvt. Ltd., Alexander Brosh, Global Sales Manager at Getriebebau NORD GmbH & Co. KG, P. L. Muthusekkar, General Manager at NORD DRIVESYSTEMS Pvt. Ltd.)

NORD DRIVESYSTEMS has committed INR 45 mn (approx. EUR 600,000) to the expansion of its Indian subsidiary. The investment was used to establish a new service area at the NORD DRIVESYSTEMS Pvt. Ltd. facility in Pune.

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he factory now boasts a 13,000 m² shop floor and can turn out over 24,000 drives per year. Since 2005, the company has delivered more than 100,000 geared motors to customers across the subcontinent. Short delivery times and fast service are among the most important measures to keep regional customers satisfied. Staffed with a team of experienced, highly trained technicians, the new, expanded service area is crucial to ensure this for the future.

In addition, NORD has launched an initiative for service vehicles: they serve customers on location, quickly provide qualified customer service, and are even equipped to offer training. www.nord.com

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P. L. Muthusekkar (NORD India) and Jutta Humbert (Managing Partner at Getriebebau NORD, Germany) open the new service area with an important customer from the construction industry, Ashok Tanna, Managing Director at Linnhoff India Pvt. Ltd. 18 | Industry Asia Pacific | January 2017

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NEWS

NEW XFT 2500SPEED FOR HIGHEST FINEBLANKING REQUIREMENTS

The new version of the XFT 2500speed from Feintool offers new possibilities for fineblanking production.

The reinforced model of the XFT 2500speed press offers an effective solution for the special challenges in fineblanking production and sets new standards.

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his model is equipped with stronger knuckle joints.

This increases the press force at the tip to 3000 kN (time-limited). For the user of the XFT 2500speed, this modification means new possibilities in fineblanking production. Due to the additional reinforcement, this model is also suitable for parts made of high-tensile materials with thicknesses of up to 8 mm at more than 100 strokes per minute. This means a lower load on the press during operation with conventional tools and greater flexibility due to the occasional use of tools with higher power requirements.

In addition, Feintool has equipped the new XFT 2500speed with a lot of innovations that ensure the highest productivity and perfect quality of the fineblanking parts. This includes increased stiffness and a quick-change system for tools.

The latest control technology and innovative energy management are also part of the new press model. In addition, the new XFT 2500 speed is equipped with FEINmonitoring, the intelligent analysis and maintenance tool and Feintool's contribution to industry 4.0 A video of the XFT 2500speed (English version) in practice is available at www.feintool.com/powerpackage

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www.tekinfo.link/r2dd6091316

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NEWS

COMPACT BIDIRECTIONAL DATA MEMORY MODULE IO-LINK MEMORY MODULE

Balluff offers a compact, bidirectional data memory module for tight mounting spaces. The compact memory module with IP 67 protection is just 34 x 16 x 8 mm in size and can be used as a memory storage device on interchangeable units such as milling heads on gantry type machining centers.

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his means the assemblies can carry their actual operating data along with them. With the following advantage: When a machine is changed, all the data such as the number of use cycles, shock and vibration values or lubrication and oil change intervals are directly loaded.

The work required to install and parameterize the module is minimal. Only a single standard cable is required for stable, fault-free, bidirectional data transmission between the milling head and controller. The cable is connected to the milling head interface in the system ring. Data transmission is noise-immune as well as resistant to EMC effects. The module can hold a total of 14 segments of 64 bytes each.

Machine operators will profit from the fact that when a milling head is switched from one machine to another, all the identifying and usage data will be automatically copied and loaded from the milling head memory into the NC controller through a cable. When maintenance or repair work is needed, the service personnel can read out all the data from the memory chip on a PC or laptop and update it as needed. This gives the plant operator continual and transparent information about the current status of the milling head.

Once again IO-Link proves to be a key technology for highperformance, space-saving Industry 4.0 concepts. www.balluff.co.uk MORE INFORMATION 18 | Industry Asia Pacific | January 2017

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NEWS

IXXAT INPACT PCIE MINI CARD ENABLES PCS TO COMMUNICATE ON PROFINET IRT FIBER OPTIC

HMS Industrial Networks expands the IXXAT INpact multi-protocol card series with a PCIe mini variant for PROFINET IRT Fiber Optic.

Designed for secure data transmission in harsh environments The IXXAT INpact enables easy implementation of a PROFINET IRT Fiber Optic Slave interface and can be used in compact industrial PCs as well as in mobile devices. Typical use cases are coupling of subsystems with superordinate networks, visualization of process data on human machine interfaces (HMIs) as well as data acquisition in PC-based process devices. IXXAT INpact is fully compliant with the requirements of the AIDA (Automation initiative of German automobile manufacturers) for a PROFINET interface.

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PROFINET IRT via fiber optic meets the highest requirements for interference immunity and data transmission. It is often used in critical areas in the automotive field, e.g. in robotic cells for car body construction, in automated welding systems and other areas with high electromagnetic interferences.

Hardware concept of the IXXAT INpact multi-protocol card series The new PROFINET IRT Fiber Optic card is the newest member of the IXXAT INpact series which supports a variety of Industrial Ethernet and fieldbus protocols, such as PROFINET, EtherCAT, EtherNet/IP, Powerlink, ModbusTCP and PROFIBUS. The multi-network capability of INpact is based on the proven Anybus CompactCom technology from HMS – used within millions of devices globally.

The FPGA-based Anybus NP40 network processor includes all functions required to handle the communication between the Industrial Ethernet or fieldbus network and the PC-based customer application. The FPGA has a low latency and a deterministic real-time behavior, making it ideal for demanding industrial applications. The PROFINET IRT FO connection is made via SC-RJ connectors. Other network standards are supported by corresponding Sub-D9 or RJ45 Ethernet interfaces.

The IXXAT INpact is offered as a dedicated version for each network with pre-installed network protocol. Furthermore, INpact is also available as a Common Ethernet version, a highly flexible and open version in which the desired industrial Ethernet protocol can be flashed by the user.

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Connection to the customer application The IXXAT INpact is supplied with a comprehensive driver package for Windows and Linux, which allows a fast and easy development of customer-specific applications, regardless of the used card type or protocol. Thanks to a universal programming interface, users can change between INpact cards and protocols without changing the customer software, which leads to increased flexibility and a significant reduction of the development costs. Support for real-time operating systems such as RTX, Intime, VxWorks and QNX is available on request.

Further information on the IXXAT INpact can be found at www.ixxat.com/inpact

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NEWS

CYCLE TIME REDUCED FROM 41 SECONDS TO 27 SECONDS ProfitTurning™ - The cutting edge of tomorrow’s CAD/CAM software.

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rofitTurning™, releases in the latest version of the ESPRIT CAM software, represents years of ground-breaking research. A lathe roughing strategy that significantly reduces machine cycle time, ProfitTurning™ has hurdled a grueling series of tests, delivering a performance that promises to take machinists, engineers and industrialists to greater levels of precision, quality control and productivity.

ProfitTurning™ is a high-speed lathe roughing strategy developed by DP Technology Corp. for OD/ID/face cutting and other tasks. Fast, secure and efficient, it also extends tool life by significantly minimizing wear. Compared to conventional ramping methods, ProfitTurning™ reduces machine cycle time as well as the frequency tooling inserts need to be replaced.

DP Technology’s R&D Director of Product and Engineering Ivan Kristic reveals the science behind ProfitTurning™’s performance:

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“ESPRIT 2016’s ProfitTurning™ toolpath maintains consistent cutting forces and chip loads, allowing cutting speeds to be significantly increased. By employing trochoidal turning and controlled engagement techniques, the ProfitTurning™ toolpath also reduces vibration and residual stresses, which in turn makes it particularly well-suited to thin walls or hard materials, especially super alloys. The net result is significantly reduced cycle times and maximized productivity.”

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Physics-Based Cutting Engine ESPRIT 2016 uses a physics-based cutting engine which provides the foundation for the technologies such as ProfitTurning™.

While traditional cutting strategies consider only the geometry of materials, ESPRIT 2016 taps deeper into the science of how different industrial materials can be cut in the most efficient ways possible. Its new toolpath technology uses the principles of physics to formulate unique strategies for each cutting challenge.

To do that, ESPRIT 2016 inputs all relevant factors in the toolpath algorithm such as tool material, tool shape, workpiece material, tool speed, feed rate, chip deforming, chip load, machine tool power, acceleration and deceleration. This helps establish complete control of the cutting environment, allowing for optimal cutting everywhere along the toolpath.

For more details about this new technology, please read the ESPRIT 2016 ProfitTurning™ White Paper available at www.espritcam.com/products/profit-turning

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SMART DRIVE ASSUMES LOCAL CONTROL

In case of an intentional or accidental disconnection of the central control system, the inverter PLC can execute preprogrammed procedures to keep the application running or bring it to a defined standstill.

Enabling centralized as well as autonomous operation.

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requency inverters from NORD DRIVESYSTEMS can react flexibly in case of disrupted communication with a central control system.

The on-board, pre-programmed PLC can take control, initiate a defined state for halting operations, or keep the application running. In process plants this can help avoid costs, for instance by preventing spoiled batches. In manufacturing facilities, material flow can be maintained.

As NORD intelligent drives feature various interfaces and are able to evaluate sensor and actuator data, optimal integration in the application is ensured. Autonomous control capability obviously has other uses beyond fallback

scenarios. In some instances, users may wish to deliberately switch the smart drive over to local control. For set-up, testing, or maintenance, the distributed frequency inverter can additionally be equipped with switches for manual drive direction and speed control.

The integrated PLC functions are programmed using IEC 61131-3 “Structured Text” or “Instruction List” text-based languages. For straightforward, user-friendly application development, NORD CON software is provided without any charge or license fees. www.nord.com

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TEN SIMPLE STEPS TO PEAK PERFORMANCE AND PRODUCTIVITY

Figure 1: NEXT STEP – total integrated production model

All machining shops face the same task: converting raw material into finished workpieces. The products must be machined to the specified level of quality, completed in the required quantity and delivered within the desired amount of time. Sustainability considerations and environmental issues must be resolved as well. To remain competitive and profitable, shops continually seek the most economical and productive ways to accomplish their work.

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he ultimate example of those process improvement efforts today is what is called in Europe “Industry 4.0” – strategy and tactics that integrate state-ofthe-art data acquisition, storage and sharing technologies into the manufacturing process. Industry 4.0 is presently the top level of manufacturing evolution, requiring strong management commitment, specialised personnel and significant investment.

Figure 1: NEXT STEP – total integrated production model MORE INFORMATION

Unfortunately, shops that lack the extensive resources of global industrial giants such as General Electric or General Motors may feel that productivity improvements are out of reach. However, simple, cost-effective analyses and actions can have a large positive effect on the productivity of small to medium-size operations. In fact, before investing in new computers, robots or personnel, any shop, large or small, should perform basic process analysis and organise current 18 | Industry Asia Pacific | January 2017

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equipment and practices. The truth is that computerisation of disorganised shop operations results only in computerised disorder.

Three phases and ten simple steps Organisation of shop practices begins by viewing the production process as three phases. First is a selection phase, involving choices of cutting strategy, tools and cutting conditions. The next phase is collection, in which the selected tools and strategies are grouped together in a machining process. Realisation is the third phase and puts the process into action.

In a large number of cases, the results of phase three fails to meet expectations, and certain steps are needed to bring reality in line with preparation. The steps can be technical in nature, such as seeking ways to moderate cutting forces, or economic, including actions to reduce costs. Fortunately, there are ten simple steps that will enable a shop to analyse

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Figure 2: Different selection criteria for tooling

Figure 3: The two-step model for cutting condition selection

and improve its metalworking operations. They are as follows.

Intelligent budget control A common approach to budgeting in metalworking operations is to acquire every element of the process at the lowest price possible. However, it is best not to base tool selection on price alone. Before discussing prices, a shop should consider the desired end results. If a tight-tolerance, top quality part is the goal, more-expensive precision tooling will be required to machine it.

Figure 2: Different selection criteria for tooling The cost of struggling with bargain tools to achieve high part quality and producing unacceptable parts will exceed the expense of higher-priced tooling. On the other hand, when quality demands are less stringent, a portion of the capabilities of high-precision tools will be wasted.

Recognising the ultimate goal of the process is the first step in cost-effective purchasing decisions.

Figure 3: The two-step model for cutting condition selection Nonetheless, simply reducing cutting parameters overall is not an intelligent way to deal with process constraints. For example, changes in depth of cut have a greater effect on the consumption of machine power than changes in feed rate. The combination of decreasing depths of cut and increasing feed rate can improve productivity within the constraint of limited machine power.

Tool application rationalisation Considering the massive number of tool geometries, sizes and materials available, the possible configurations of metalcutting tools are practically endless. Machine shops typically make tool application choices one operation at a time, choosing a specific tool to create a certain feature on a part and then picking another tool to machine another different feature.

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Intelligent handling of constraints Real-world metalworking operations, as opposed to theoretical discussions of metalworking theory, are bound by practical constraints that include machine power and stability and customer demands regarding dimensions and surface finish quality. Cutting conditions can be varied over a wide range, but the effects of different combinations of

parameters on cutting forces and surface finish may limit some choices.

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Figure 4: The total offer for tooling is enormous – rationalisation is the key

Figure 4: The total offer for tooling is enormous – rationalisation is the key In an example case, two separate tools would be used to turn a shaft and produce a wide groove with two square shoulders. Specifically, one tool turns the shaft to the desired diameter and cuts one shoulder and the width of the groove, followed by a second tool that cuts the other shoulder. Each tool is programmed and optimised separately, representing separate programming and administrative costs.

A contrasting tool selection strategy is to develop a highlyspecialised custom tool that can create multiple features in one machining pass. The strategy is convenient but the design and manufacturing of special tools is expensive.

Between the two extremes is an approach that utilises a standard tool engineered to perform more than one operation (multi-directional tooling). A perfect example of this approach is a Seco’s MDT tooling.

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The tool’s features enable it to turn the diameter, plunge in to create one shoulder, move across the shaft to cut the groove, then withdraw to form the second shoulder. Even if such a multidirectional tool does not operate at the optimised cutting parameters of the two separate tools, the savings in tooling, programming, tool change time and inventory costs make the multidirectional tool the preferred choice.

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Complex workpiece approach (group technology) Comparable to the technique of applying tools that combine two or more operations, a shop can choose tools that are capable of creating similar features across a range of workpieces. A shop may machine a wide range of different workpieces, but the workpieces will share common features such as holes, slots and milled surfaces.

To expedite the machining of complex parts, a shop can view similar features as a group and choose a tool optimised for a certain operation, such as holemaking, that is repeated on different parts. The optimised tool maximises productivity and also reduces cost when considering the engineering time that goes into repetitively programming tools for each separate part. The group technology approach also helps reduce tool inventory.

Achieving minimal functional workpiece quality Although the concept initially may seem strange, shops must realise that it is necessary to achieve only the lowest possible workpiece quality that meets customer specifications and functional requirements. There is no need to exceed those requirements. If a part tolerance is 5 microns, achieving 3 microns is a waste of time and money. Higher quality tooling and more precise operating processes will be required to achieve the tighter tolerance. But customers will refuse to pay for such unrequested higher quality, and the job will be a money-losing proposition for the shop.

NEWS Figure 5: Total quality of a finished workpiece is influenced by a big number of elements

Figure 6: Cutting tools wear out due to different phenomena

Figure 5: Total quality of a finished workpiece is influenced by a big number of elements Some quality issues, such as burrs, obviously must be resolved. And there are situations where minor cost considerations are irrelevant – tool cost differences of a few Euros or cents are meaningless when compared to the value of a large titanium aerospace component the tool will machine. To maximise cost efficiency, a shop should tailor production quality to the functional and quality requirements of the workpiece.

Predictive tool maintenance Traditional tool maintenance is reactive. When a tool wears out or breaks, it is replaced. That approach, however, generates costs beyond those of the tool itself, including manufacturing process downtime and possible damage to the workpiece. Preventive tool maintenance is a step beyond reactive maintenance.

Figure 6: Cutting tools wear out due to different phenomena

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The useful lives of even identical tools usually vary above and below an average length of time. Preventive tool maintenance is based on replacing the tool before it reaches its shortest expected working life to be sure that the change is made before the tool wears out too much or breaks. That approach, however, wastes tools with a tool life that is at or above average.

A relatively new approach, based on tool life modeling, uses computer calculation and simulation to provide predictive data on tool deterioration and to indicate when replacement is due. At a somewhat greater expense, use of sensors can further fine-tune the results by tracking tool wear in real time. Use of predictive tool maintenance has the potential to reduce tooling costs by 15 percent, 20 percent or more. >>> 18 | Industry Asia Pacific | January 2017

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Figure 7: Productivity and cost efficiency can be achieved through different roads

Tool inventory control When dealing with the second – collection – phase of metalworking production, it is important to note that tool inventory control is different than tool management.

Tool management refers to organising an existing tool inventory and making it available for production. For that task, a variety of automated tool management systems is available. Tool inventory control, on the other hand, is an effort to rationalise and consolidate the number of tools a shop possesses to focus on what is really needed. If tools are not rationalised before being loaded into an automated tool dispenser, the result is simply automated disarray.

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Practical work analysis In his 1907 book “On the Art of Cutting Metals” American engineer and work analysis pioneer Fredrick Winslow Taylor noted that some of the activities in a workshop, such as milling a surface, clearly add value to a workpiece. On the other hand, he noted that many activities that are necessary for the production of a finished workpiece do not directly add value. These include e.g. fixturing the workpiece on the machine or writing the machining program.

Taylor said that non-value-adding tasks should be completed as fast as possible and in a way that minimise their effects on the total costs of production. Automation can accomplish tasks such as part loading and fixturing and save time and money.

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Figure 7: Productivity and cost efficiency can be achieved through different roads Manufacturers typically believe that the best way to reduce processing time is to increase machining parameters.

Most shops do not fully recognise the time consumed by activities such as engineering. A task that can represent as much as 40 percent of the total time for a part to travel from

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Figure 8: Developments in machining processes

drawing to delivery. Unplanned downtime caused by tool failure, quality issues or chip control problems also may be overlooked. When analysing work activities and costs, it is essential to consider all the contributors to part production time.

(See sidebar next page) Practical application of optimisation The third phase of metalworking part production, the realization phase, puts into action the tools and strategies selected in phase one and collected in phase two. Rarely if ever does a process work exactly as planned, and it is at this point where optimisation of the operations in terms of speed, reliability and other factors is necessary. Additionally, most shops also seek to improve ongoing processes. After carrying out the organisation and rationalisation steps of phases one and two, practical optimisation enables a shop to find technical and economic benefits in a combination of feed, speed and depth of cut that produces the desired results.

potential effects of the fluids on the environment as well as the cost of safely disposing them. Growing use of lead-free workpiece materials is aimed at removing the harmful metals from the environment. Improving process parameters and production tooling performance will result in measureable savings in energy expenditures.

Figure 8: Developments in machining processes >>>

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Intelligent introduction of new technology Manufacturers today face a range of relatively new challenges including mandates for sustainability and environmental protection. Intelligent introduction of new technologies and processes enables shops to fulfill the challenges. Dry machining, for example, permits a facility to reduce the use of coolants, which in turn reduces the 18 | Industry Asia Pacific | January 2017

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Figure 9: Total STEP offer

TRACKING ELUSIVE COSTS

Conclusion: phase 4 and STEP education As manufacturers of any size utilise the ten simple steps to improve their operations, a fourth phase of the production process involves ongoing internal education. The goal of that education is to ensure shop personnel realize solutions to productivity issues do not always necessitate huge investments, high technology and expanded workforces.

The lessons learned while improving an operation or a family of operations can be reapplied and expanded to include similar situations throughout an entire shop. These lessons can be supplemented with organised education such as the Seco Technical Education Program (STEP), a well-developed and practical program designed to familiarise users with the latest tooling systems and techniques. Combined with practical experience in process analysis and improvement, education is the key to establishing a culture of problemsolving and process improvement that will result in ongoing manufacturing success.

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Figure 9: Total STEP offer By: Patrick de Vos, Corporate Technical Education Manager, Seco Tools www.secotools.com

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When performing practical work analysis, costs may be obvious, hidden or overlooked. The factors affecting the total cost of converting raw materials into a finished workpieces can generally be grouped into eight categories. The categories include tools and tooling systems; workpiece materials; processes and process data; personnel and organisation; maintenance; special factors; peripheral equipment; and various random factors.

Processing time is the most obvious cost factor, and it includes machining time as well as the time spent in machine and tooling setup, work handling operations and quality inspection. It is clear that a planned amount of downtime is necessary for setup and workhandling, but a less apparent subset of processing time is unplanned work stoppages resulting from unanticipated tool deterioration, chip problems and inconsistent quality.

Unreliable machining processes that produce poor quality or rejected parts, broken tools, damaged workpieces and systems problems needlessly increase process times and expense. The factors at the forefront, such as machining time and scheduled tooling replacement, may contribute less to overall processing time than the effects of operator errors and system anomalies.

Engineering – consisting of general, geometric (programming) and technical (selection of tooling and machining parameters) activities – is often overlooked as a contributor to overall production time. Part programming represents a significant portion of engineering time, but a large amount of engineering activity is also consumed in technological issues such as tool selection and choice of machining parameters.

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