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Process Improvements[1]

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Process Improvements[1]

  1. 1. Process Improvements Steve Taylor FMF Supervisor
  2. 2. VCN 40T Spindle <ul><li>Deep Bore Process exceeded 1hr 10 min . </li></ul><ul><li>Chip Control issues. </li></ul><ul><li>Machine load concerns for production demands . </li></ul><ul><li>Reduced cycle time by 81%. </li></ul><ul><li>New cycle time 22 min </li></ul><ul><li>Changed program to optimize tooling. </li></ul><ul><li>Changed depth/cut and speed/feed ratio for better tool life and chip control. </li></ul><ul><li>Replaced Sandvik with SECO inserts. </li></ul>SECO - CNMG 432 TP1500 SECO - 32.51 TP1500
  3. 3. 200/250 STD Headstock <ul><li>Cycle time for bore application 60min . </li></ul><ul><li>Manpower could not keep up with demand. </li></ul><ul><li>High Level of reported MDR’s </li></ul><ul><li>Reduced cycle time by 50%. New cycle 30min </li></ul><ul><li>Additional manpower eliminated for current machine schedule. </li></ul><ul><li>One and done concept </li></ul><ul><li>Implemented SECO boring technology. </li></ul>
  4. 4. 300/350 STD Headstock <ul><li>Cycle time for Headstock application 180min . </li></ul><ul><li>Manpower could not keep up with demand. </li></ul><ul><li>High Level of reported MDR’s </li></ul><ul><li>Reduced cycle time by 50%. New cycle 90min </li></ul><ul><li>Additional manpower eliminated for current machine schedule. </li></ul><ul><li>One and done concept </li></ul><ul><li>Implemented SECO boring technology. </li></ul>
  5. 5. VCN Clamp Cylinder <ul><li>Cycle time 1.8hrs </li></ul><ul><li>Long turn around </li></ul><ul><li>High production part </li></ul><ul><li>Reduced cycle time by 50%. </li></ul><ul><li>New cycle time 50min . </li></ul><ul><li>Adjusted program to optimize current tooling. </li></ul><ul><li>Implemented Ceramic technology from Sandvik. </li></ul>
  6. 6. 200/250 Rotor Sleeve <ul><li>Cycle time 1.2 hrs </li></ul><ul><li>Undesirable tool life </li></ul><ul><li>Chip control issues </li></ul><ul><li>Man operation due to poor process </li></ul><ul><li>Reduced cycle time by 50%. </li></ul><ul><li>New cycle time 40min . </li></ul><ul><li>Implemented SECO insert. CNMG 432 TP1500 </li></ul><ul><li>Changed cutting data to control chip breakage and tool wear. </li></ul>
  7. 7. STD 200/400 Turrets Old New Old Process New Process Cutter - RA245-152 Insert - R245-18T6 Speed - 750RPM Feed - .3 Cutter - RA365-101 Insert - R365-1505 Speed - 4000RPM Feed - 1.4 Old New 12% Reduction
  8. 8. Semi/Finish Tooling for Headstock Cutter - R220-100-63 Insert - TNGN 22 PCBN Speed - 6000RPM Feed - .6 PER REV Cutter - R220.96-100 Insert - XNEX 080608TR Speed - 1000RPM Feed - 1.0 PER REV CYCLE TIME OLD - 2.35 HRS NEW - 1.4 HRS 48% REDUCTION Semi-Finish Finish
  9. 9. MU-8800 Cutter - R290-100-63 Insert - R290 -12 03 6090 Speed - 1000RPM Feed - 1.0 PER REV 23% 44% 40%

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