CNC Machine Work Study - Productivity Improvement Based on Machine and Machine Work Redesign

Aspects of Machine to be Studied in Machine Work Study

Advanced Machine Availability
Replacement
Condition of the Machine (Repair & Overhaul Need)
Improvement of the Machine
Accessories
Cutting Tools
Machine Speeds
Setup Procedure
Upkeep of the machine by operator
Power consumption
Breakdowns analysis
Data Generation and Analysis

Machine Time Study - Machine Time Estimation or Calculation

Machine Time Study - Machine time study helps in locating machine related issues for in depth studies for reducing machine time required for a job.  Every industrial engineering study is begun with a observation of present time taken and at the end of the study, new reduced time is also measured. The new process plan of the job reflects the industrial engineering improvements and the reduced time for operations.

Advanced Machine Availability

As a part of Machine work study, availability of advanced machines can be ascertained and a study is done to evaluate buying the new advanced machine.



Top 5 CNC Machine Manufacturers in the World
https://www.plantautomation-technology.com/articles/introduction-to-cnc-machining-top-5-cnc-machine-manufacturers-in-the-world

By type, the CNC machine market is categorized into CNC lathe, CNC milling, CNC grinding machine, CNC welding, and CNC winding. CNC lathes are the most sought CNC machines, as they are multi-purpose in nature and are used in a wide range of applications. CNC machining centers are the second most employed CNC machine type. Both of them collectively encompass about 50.08% market share of CNC by volume.
https://www.globenewswire.com/news-release/2019/07/16/1883217/0/en/Global-CNC-Machine-Market-Will-Reach-Over-to-USD-100-9-Billion-By-2025-Zion-Market-Research.html


Okuma Machine Selector
https://www.okuma.eu/products/machine-selector/


Ultra-Precision with the Largest Workspace, in the Smallest Footprint
Machining Large Precision Parts Is Difficult and Can Be Costly to Produce
The larger the part, the greater the chance you have of not achieving a successful result. Precisely setting-up or repositioning parts because you don’t have the machining area can lead to errors—or worse. Working on existing parts that are already of high value is stressful and risky.

Minimize your risk and get the machining right—the first time.

Transform Your Business, Reduce Rejected Parts, and Take the Stress out of Large Part, High-Tolerance Jobs
M10 Pro in Action
 High speed machining with a 40,000 RPM, 3 kW HSK spindle
 Thermally balanced rigid construction with a solid granite table
 Exact precision with brushless servo motors and linear scales in all axis
https://www.datron.com/products/cnc-milling-machines/m10-pro/


Automatization of Machine Tools and CNC
https://books.google.co.in/books?id=od9YDwAAQBAJ&pg=PA44#v=onepage&q&f=false

CNC Machines in Industry 4.0
https://books.google.co.in/books?id=nr_ADwAAQBAJ&pg=PA102#v=onepage&q&f=false

Replacement

Based on repair cost and operating cost, analysis is to be done regarding replacement of the machine by the same model or by a different machine.

Is it time to replace my CNC machine?
July 2, 2019
https://mfgtechupdate.com/2019/07/time-replace-cnc-machine/


Condition of the Machine (Repair & Overhaul Need)
As  part of machine work study, the condition of the machine is to be evaluated for recommend-ing overhaul if needed.
Whether adequate maintenance is being done or not is investigated

Improvement of the Machine

Industrial engineers have to find if any improvement of machine can increase productivity.
In Toyota improvement of machines is an important activity.

Machine Work Study - Machine Improvement in Toyota Production System (TPS)
https://nraoiekc.blogspot.com/2019/11/machine-work-study-machine-improvement.html

Accessories

Investigate if any machine accessories are available which can increase productivity.

The Benefits of CNC Machine Tending With Collaborative Robots
By Robotics Online Marketing Team
04/16/2019
https://www.robotics.org/blog-article.cfm/The-Benefits-of-CNC-Machine-Tending-With-Collaborative-Robots/156

Cutting Tools

Are appropriate cutting tools used for various operations?
Cutting tool planning is required so that tools are available when needed.

2/4/2019
CNC Lathe Advances Breed Novel Cutting Tool Designs
A Turning Tool in a Milling Spindle

FreeTurn is a turning tool from Ceratizit (ceratizit.com). It takes advantage of the capabilities of combination turning/milling centers to enable traditional turning operations—roughing, finishing, contour turning, face turning and longitudinal turning—to be done, without pause, with a single tool. This saves lots of time and money.
Parting in Y

Another tool designed to leverage improvements in CNC lathes is the CoroCut QD parting tool from Sandvik Coromant (sandvik.coromant.com).
https://www.adandp.media/articles/cnc-lathe-advances-breed-novel-cutting-tool-designs

Machine Speeds: Cutting Speed, Feed, Depth of Cut

Machine speed optimization was done by F.W. Taylor.
Many research studies are being done even in the current years.
For each machine, relevant speed analysis     has to be done by industrial engineers as     part of Machine work study.


Effect of machining variables and coolant application on HSS tool temperature during turning on a CNC lathe
Article (PDF Available) in IOP Conference Series Materials Science and Engineering 413(1):012004 · September 2018
T Ejieji
Cutting variables in the operation of a Computerized Numerical Control (CNC) lathe machine can affect parameters such as the work piece, tool temperature, material surface finish, material properties and vibration. A programmable CNC lathe machine was used in this work to examine the effect of different cutting variables on HSS tool temperature. Carbon steel material of C20 carbon equivalent and ferritic stainless steel was machined at different cutting speeds, depth of cut with an HSS tool. A constant feed rate  of 7 mm/minute was maintained throughout the experiments. Temperature profiles were obtained for different depth of cut ranging between 0.5 and 2.5 mm and cutting speed range of 500 to 800 rpm.  Tool Temperatures were observed to increase with cutting speed and depth of cut. Increase in depth of cut from 0.5 to 1.5 mm resulted into a 64% increase in tool temperature while coolant application reduced tool temperature by as much as 63.2% in stainless steel. Tool life can be significantly enhanced by appropriate machining variables selection.
https://www.researchgate.net/publication/327564725_Effect_of_machining_variables_and_coolant_application_on_HSS_tool_temperature_during_turning_on_a_CNC_lathe

Setup Procedure - Single Minute CNC Setup (SMCS)

Setup time reduction is now   an important exercise related   to machines.
For each machine set up redu-ction studies have to be done by industrial engineering
  department.


Upkeep of the Machine by Operator
Scientific management of the    machine maintenance recog   nized the role of operations
   persons in machine upkeep.
Industrial engineers have to    assess the present practices    & their effect on productivity.


Power Consumption
Minimizing power consumption is an    important industrial engineering    activity.
Hence power consumption has to be    analysed and measures are taken to    eliminate waste.

Breakdowns Analysis
Breakdown analysis has to be done to examine the adequacy of preventive maintenance and predictive Maintenance.


Data Generation and Analysis
Information is also a resource.
Industrial engineers have to assess the adequacy of the information.
They also have to prevent waste.They have to examine the cost incurred for data collection.


Industry 4.0
Industry 4.0 is increasing the role of machines and information collection and transmission in production systems.
Hence industrial engineers have to be increase their effort on machine data collection using sensors and the data analysis through edge computing and cloud computing.



Tips

10 Tips to Better CNC Turning
2017
https://kentcnc.com/10-tips-to-better-cnc-turning/

Machine Time Study - Machine Time Estimation or Calculation

Are Imprecise CAD/CAM Cycle Time Estimates Holding Back Efficiency?
4/20/2018
https://www.mmsonline.com/blog/post/are-imprecise-cadcam-cycle-time-estimates-holding-back-efficiency


Estimation of Machining Time for CNC Manufacturing Using Neural Computing
International Journal of Simulation Modelling 15(4):663-675 · December 2016 
https://www.researchgate.net/publication/311646006_Estimation_of_Machining_Time_for_CNC_Manufacturing_Using_Neural_Computing

Mechanistic approach to predict real machining time for milling free-form geometries applying high feed rate
The International Journal of Advanced Manufacturing Technology, February 2010, Volume 46, Issue 9–12, pp 1103–111
https://link.springer.com/article/10.1007/s00170-009-2183-8


COSTIMATOR® by MTI Systems Slashes Machining Cost Estimating Time, Boosting Quoting Accuracy, Consistency and Profitability
https://www.mtisystems.com/articles/article_june_09.html



Estimating Machining Time for Turning
https://nraoiekc.blogspot.com/2014/04/estimating-machining-time-for-turning.html

Milling - Estimation of Machining Time
https://nraoiekc.blogspot.com/2019/11/milling-estimation-of-machining-time.html






About CNC Machining

https://www.3dhubs.com/guides/cnc-machining/


Related Articles


Machine Work Study - Machine Improvement in Toyota Production System (TPS)
https://nraoiekc.blogspot.com/2019/11/machine-work-study-machine-improvement.html

Machine Work Study - Productivity Improvement Based on Machine and Machine Work Redesign
https://nraoiekc.blogspot.com/2019/06/machine-work-study-productivity.html

Machine Work Study:  Methods, Techniques and Tools
https://www.youtube.com/watch?v=0Bf6cq9-YU4

Machine Work Study
https://www.youtube.com/watch?v=b31oEBYu-T4