Taylor's Industrial Engineering - Machine Shop Process Industrial Engineering.
Yes Taylor's Industrial Engineering is first machine effort improvement to increase productivity and then human effort engineering to reduce human effort involved in operating machines. Of course, in pure human effort tasks, there is no machine. In such tasks, industrial engineers have no special advantage in design and improvement tasks. Of course, special techniques and methods were developed in scientific management and industrial engineering areas to study human effort. But still in pure human effort tasks, the engineering expertise is not required.
What is Industrial Engineering?
Industrial engineering is system efficiency engineering. It is done on products, facilities and processes.Its primary tasks in the area of processes are machine effort industrial engineering and human effort industrial engineering. - Narayana Rao.
Industrial Engineering:
Activity related to developing the most efficient ways to utilize people, assets, materials, information, and energy to make a product or service. - Novartis
https://nraoiekc.blogspot.com/2020/04/industrial-engineering-novartis-way.html
Industrial engineering is Shop Floor (Gemba) based (現場) continuous engineering of products and processes to increase productivity/efficiency/cost reduction
80 - 20 Rule in Industrial Engineering - 80% Engineering changes - 20% Change in Human Motions and Movements
https://nraoiekc.blogspot.com/2019/11/80-20-rule-in-industrial-engineering-80.html
EBook Free Download. MODERN INDUSTRIAL ENGINEERING. 7150+ DOWNLOADS so far.
PRODUCT INDUSTRIAL ENGINEERING (Value) - FACILITIES INDUSTRIAL ENGINEERING (Lean) - PROCESS INDUSTRIAL ENGINEERING (Minimizing Effort - Machine - Man). Industrial engineers manage cost reduction and productivity improvement and contribute directly to profit increase.
Machine Shop Industrial Engineering
Knowledge for Machine Shop Industrial Engineering
Machine Shop Technology and Process Cost Reduction News
2021 - 2020 - 2019 - 2018 - 2017 - 2016 - 2015 - Up to 2014
Productivity Improvement in Machine Shop - F.W. Taylor - Basic Theory and Foundation (1895 to 1912)DFMA - Design for Machining - Summary Notes
__________________
Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity
Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering
Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering
Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering
Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers
Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.
Motion Study - Human Effort Industrial Engineering
Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements
Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management
An improperly designed tool may wear or chip rapidly or unpredictably, reducing productivity, increasing costs, and producing parts of deteriorating quality. Tooling thus has a major influence on the productivity and economics of a process.
Cutting-tool material and design have a strong impact on machining performance. Properly designed tools produce parts of consistent quality at higher cutting speeds and feeds and also have long and predictable useful lives. An improperly designed tool may wear quickly or chip rapidly or unpredictably, reducing productivity, increasing costs, and producing parts of deteriorating quality. Tooling has a major influence on the productivity and economics of a process. Therefore it is important to consider all material options and tooling geometries for a given application with associated range of speeds and feeds and their typical failure modes. In high-volume applications, perishable tooling costs are typically 3% of the component cost. Using higher cost tool capable of running at higher material removal rates (MRRs) normally is profitable since a 20% increase in the MRR could reduce the total cost per component by 15%. Modifying tooling to increase tool life can also be attempted as 50% increase in tool life reduces the total cost per component by 1%–2%.
Industrial engineers have to take measurements of machining operations in the areas of time, cost and productivity at the start of the engineering study as well as at the end of the industrial engineering study. Measurements are taken at the start of the study as through literature review or secondary sources, alternatives that offer less time, or less cost or more productivity can be selected. The measurements taken at the beginning of the study are also important for guiding thinking in brainstorming exercises that are done after the group members do focused study of the existing knowledge. Measurements at the end of the study validate the improvements made and provide the standards for further operations.
Time Measurement also termed work measurement
Cost Measurement (Cost Accounting - Cost Estimating)
Productivity Measurement (Output for each input of various resources, as well as combinations resources)
Ford began investigating alternatives to conventional flood coolant machining technology for aluminum materials in the 1990s through a collaborative project seeking to completely eliminate coolants with an aim towards completely dry machining of aluminum. Many machining operations for ferrous components were already dry. The project was carried out through extensive laboratory trials and a series of small-scale production pilots in early 2000s
Ford began applying MQL to aluminum transmission components in 2005, and by 2008 had over 200 MQL machining centers in operation machining aluminum transmission cases, torque converter housings, and valve bodies at two plants in North America. MQL machining became Ford’s current standard machining method for these components, and is being implemented in new high-volume machining lines globally. Ford began machining aluminum engine heads and cast iron engine blocks in 2011. MQL is now the primarily standard method for machining cast iron engine blocks and aluminum engine blocks and heads. For some specialized operations still wet machining is used . MQL machining modules are being installed in plants in new locations like Brazil and China.
Ford is making effort to extend MQL machining to additional components like CGI engine block machining, thermally sprayed engine bore machining, and aluminum deep hole drilling. There are technical challenges and the research community and engineering community are involved in finding solutions and extend MQL to new areas of application.
Source:
Minimum Quantity Lubrication (MQL) in Automotive Powertrain Machining
Bruce L. Tai, David A. Stephenson, Richard J. Furness, Albert J. Shih
6th CIRP International Conference on High Performance Cutting, HPC2014
Procedia CIRP 14 ( 2014 ) 523 – 528
doi: 10.1016/j.procir.2014.03.044
More papers given in: Optimization of Machining - Bibliography
Taguchi-Based Six Sigma Approach to Optimize Surface Roughness for Milling Processes
Authors: Joseph C. Chen, Sky Chou
2007
This illustration focuses on using Six Sigma methodologies to improve the surface finish of a manufactured part produced by the CNC milling machine and reduce defects produced by the operation. Milling of aluminum is operation. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that lead to reduced variability in surface finish specified by the customer. A L9 orthogonal array was applied in the Taguchi experimental design, The controllable factors are feed rate, depth of cut, and spindle speed, The confirmation run with the optimal parameters determined in the study confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The study confirms that the Taguchi–based six sigma approach can be efficiently used to reduce defects by minimizing variation of the operation and improve the process capability index of the CNC milling process.
https://publications.waset.org/10007983/taguchi-based-six-sigma-approach-to-optimize-surface-roughness-for-milling-processes
More Case Studies on Six Sigma in Machining
The science of ergonomics involves designing and arranging things so that people can use them as efficiently and easily as possible. When ergonomics is applied to CNC machining the primary focus is on improving productivity and safeguarding the machine operators.
A few examples of how Gosiger Automation builds ergonomics into its systems.
Loading and unloading heavy parts.
See a video of a Gosiger Automation designed cell that uses a Fanuc r-2000 iB robot with a vision system loading and unloading a 100+ pound part delivered to it on an automatic conveyor.
Eliminating repetitive motion.
Even smaller, lighter parts present ergonomic problems best overcome with a robot. A machine operator who is constantly opening and closing the machine tool door, lifting and placing the part into position, then removing the part and loading another is performing repetitive motions that can take their toll on the person’s joints, back and extremities
Seen in a video, how a family of parts can be robotically loaded and unloaded, placed in an inspection fixture, automatically checked using a Renishaw Equator and, using software to analyze the results, make tool offsets all without operator intervention.
Allowing safe access for machine tool maintenance.
https://www.gosiger.com/news/ergonomics-robotic-automation
More on ergonomics
http://www.ilocis.org/documents/chpt29e.htm
https://webstore.ansi.org/industry/ergonomics/machine-ergonomics
http://blog.lenoxtools.com/industrial-metal-cutting/2015/11/20/machine-shops-use-ergonomics-to-increase-productivity-and-reduce-injury/
Machine Tool Analytics - Analytics for Machine Tools
MT Analytics offers Industry 4.0 solutions using data Analytics and a hardware Test Lab .
The MT Analytics GmbH is running a component test lab for machine tool and automotive components and provides services to their customers identifying and optimizing dynamical and geometrical problems of discrete manufacturing production systems. Beside MT Analytics GmbH provides Data Analytic Software solutions to optimize given NC Codes and to monitor the quality of parts as well as the condition of all machine tool components. Machine internal data are analyzed in real time by our algorithms that include our expert knowledge and the experience in testing, modeling and optimizing hardware.
Hardware Test Lab
The MT Analytics GmbH is running a Component Test Lab for machine tool and automotive components and provides services to their customers identifying and optimizing dynamical and geometrical problems of discrete manufacturing production systems
Data Analytics
The MT Analytics GmbH provides Data Analytic Software solutions to optimize given NC Codes and to monitor the quality of parts. Machine internal data are analyzed in real time by our algorithms that include our expert knowledge in testing, modeling and optimizing Hardware.
8/14/2009
Tooling Supplier's Productivity Improvement Program (PIP) gives excellent benefits
2019
Improving machining process by College students in their project work on lathes
https://books.google.co.in/books?id=bsqDDwAAQBAJ&pg=PA329#v=onepage&q&f=false
https://www.researchgate.net/publication/330360898_Time_Optimization_Implementation_in_Conventional_Lathe_Machining_Operations
Reconfigurable Manufacturing Systems: From Design to Implementation
Lyes Benyoucef
Springer Nature, 19-Oct-2019 - Technology & Engineering - 250 pages
https://books.google.co.in/books?id=0uK3DwAAQBAJ
2018
https://www.industr.com/en/metal-working-fluid-performance-in-aluminium-high-speed-machining-2351265
2013
2008
Process Planning Optimization in Reconfigurable Manufacturing Systems
By Farayi Musharavati
2008
https://books.google.co.in/books?id=ab6iQ-4SG5wC&printsec=frontcover#v=onepage&q&f=false
1996
Introduction to Machining Science
Prof G.K. Lal
IIT Kanpur
https://books.google.co.in/books?id=MTiwBJ5VbtYC&printsec=frontcover#v=onepage&q&f=false
1973
Proceedings of the Fourteenth International Machine Tool Design and Research Conference
S. A. Tobias
Macmillan International Higher Education, 1973 - Engineering - 841 pages
https://books.google.co.in/books?id=bFVdDwAAQBAJ
Updated 29.12.2023, 19.4.2022, 8.1.2022, 17.12.2021, 8.5.2021,28 May 2020, 17 May 2020, 2 May 2020
First published 27 April 2020
Principles of Industrial Engineering - Taylor - Narayana Rao - IISE Annual Conference 2017
____________________________________
Focus Areas of Industrial Engineering - Brief Explanation
Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity
Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering
Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering
Industrial Engineering Optimization: Optimizing industrial engineering solutions created in Product Industrial Engineering and Process Industrial Engineering.
Operations Research - An Efficiency Improvement Tool for Industrial Engineers
Operations Research - An Efficiency Improvement Tool for Industrial Engineers
Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering
Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers
Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.
Motion Study - Human Effort Industrial Engineering
Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements
Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management
Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.
Applied Industrial Engineering - Process Steps
https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html
Industrial Engineering - Lean Manufacturing - Parent - Child Relationship
The first major research work in the area machine shop process industrial engineering i.e., productivity improvement was done by F.W. Taylor. A series of experiments, theory development and application were done over a period of 26 years. Industrial engineers have to compulsorily read the full book or paper to understand the scope machine productivity improvement component of industrial engineering. No doubt this research work is limited to work on lathe. But that provides the framework for working on other machines and related processes.
Read the paper in the ASME Proceedings
ON THE ART OF CUTTING METALS
https://babel.hathitrust.org/cgi/pt?id=mdp.39076000032131&view=1up&seq=61&size=125
Machine Shop Product Industrial Engineering
How many Industrial Engineers can a Company Employ for Cost Reduction?
For $100 million cost, there can be one MS IE and 6 BSIEs.https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html
Industrial Engineering - Lean Manufacturing - Parent - Child Relationship
Machine Shop Process Industrial Engineering
Cost Reduction - Productivity Improvement
The first major research work in the area machine shop process industrial engineering i.e., productivity improvement was done by F.W. Taylor. A series of experiments, theory development and application were done over a period of 26 years. Industrial engineers have to compulsorily read the full book or paper to understand the scope machine productivity improvement component of industrial engineering. No doubt this research work is limited to work on lathe. But that provides the framework for working on other machines and related processes.
Read the paper in the ASME Proceedings
ON THE ART OF CUTTING METALS
https://babel.hathitrust.org/cgi/pt?id=mdp.39076000032131&view=1up&seq=61&size=125
DFMA - Design for Machining - Summary Notes
All the focus areas of industrial engineering can be utilized in the machine shop to improve operations and processes continuously and achieve cost reduction. Here are the illustrations for each relevant focus area.
Focus Areas of Industrial Engineering in Machine Shop Process Industrial Engineering
All the focus areas of industrial engineering can be utilized in the machine shop to improve operations and processes continuously and achieve cost reduction. Here are the illustrations for each relevant focus area.
Process Industrial Engineering - Process Alternatives
Cutting tool features and machining productivity
An improperly designed tool may wear or chip rapidly or unpredictably, reducing productivity, increasing costs, and producing parts of deteriorating quality. Tooling thus has a major influence on the productivity and economics of a process.
Cutting-tool material and design have a strong impact on machining performance. Properly designed tools produce parts of consistent quality at higher cutting speeds and feeds and also have long and predictable useful lives. An improperly designed tool may wear quickly or chip rapidly or unpredictably, reducing productivity, increasing costs, and producing parts of deteriorating quality. Tooling has a major influence on the productivity and economics of a process. Therefore it is important to consider all material options and tooling geometries for a given application with associated range of speeds and feeds and their typical failure modes. In high-volume applications, perishable tooling costs are typically 3% of the component cost. Using higher cost tool capable of running at higher material removal rates (MRRs) normally is profitable since a 20% increase in the MRR could reduce the total cost per component by 15%. Modifying tooling to increase tool life can also be attempted as 50% increase in tool life reduces the total cost per component by 1%–2%.
For nonferrous work materials, WC tools will exhibit 2–3 times the productivity and 10 times the life of HSS tools. In steels, they give 2 times the productivity and 5 times the life.
Sintered Tungsten Carbide (WC)
Basic guidelines for selecting carbide grades are (1) use the lowest Co content and finest grain
size, provided edge chipping and tool breakage do not occur; (2) use straight WC grades when
abrasive edge wear is of concern; (3) use TiC grades to prevent crater wear and/or both crater and
abrasive wear; (4) use TaC grades for heavy cuts in steels.
Even though the range of rake angles is generally −5° to +15°, higher positive angles are slowly being used to improve productivity.
Multipoint boring bars are often used to improve stability and to increase productivity in high volume applications.
Rotary milling cutters can be used in some applications to improve productivity.
Significant improvements in productivity have resulted from the acceptance of solid carbide drills. Compared to HSS drills, carbide drills permit an increase in productivity by a factor of 2–10, and/or increase in hole quality. Solid carbide drills are especially well suited for high throughput precision hole manufacturing.
Internal coolant is more effective; this method cools and lubricates the cutting edge and reduces thermal shock in addition to removing chips, and therefore often results in improved tool life and productivity.
The process industrial engineering illustrations use cutting tool substitution as the way to increase productivity and reduce cost.
Plataine’s ‘AI and IIoT’ in Aerospace & Automotive composites manufacturing for Productivity Improvement and Waste Elimination
October 25, 2021
The key role of ‘AI and IIoT’ in Aerospace & Automotive composites manufacturing
Siemens is integrating Plataine’s technology into their Manufacturing Operations Management (MOM) solution Opcenter. Plataine has deep domain knowledge in the field of aerospace composites and IIoT solution. AI-based algorithms analyse the data and provide smart insights and predictions to the factory floor operator to make optimized, data driven decisions across factories. The MOM solution consolidates all production processes to deliver another level of visibility on top of an MES. The result is improved quality, the ability to perform advanced planning, and better direction of product design efforts; as well as improved efficiency, flexibility, and time-to-market. Plataine brings new range of capabilities to MOM in the area of composites processing.
Real-time monitoring of raw materials
Combining AI-based IIoT technology with RFID tags allows all composite raw material rolls to be tracked in real-time as soon as they enter the factory – including monitoring of material shelf-life. AI-based algorithms proactively apply the intelligence to analyze the historical manufacturing data and offer predictions related to late work orders, material expiration and suggest actions to prevent these problems. If there is an unexpected production delay causing the ETL (expiration time left) to run low, Digital Assistants alert employees to the best course of action – which is likely to be either to use another raw material with a longer ETL. Also it alerts operators to focus on expediting finished parts into the autoclave.
Optimized cutting and kitting processes
With the Plataine-Siemens solution, ready-to-cut production plans are automatically created. The fully CAD-integrated AI software achieves optimal material utilization by taking all variables – such as dynamic customer orders – into account. To save material, the AI-based software fits as many plies into each cut plan as possible, while advanced optimization algorithms ensure optimal plans even with mixed work orders, which results in higher material yield.
IE Measurements
Industrial engineers have to take measurements of machining operations in the areas of time, cost and productivity at the start of the engineering study as well as at the end of the industrial engineering study. Measurements are taken at the start of the study as through literature review or secondary sources, alternatives that offer less time, or less cost or more productivity can be selected. The measurements taken at the beginning of the study are also important for guiding thinking in brainstorming exercises that are done after the group members do focused study of the existing knowledge. Measurements at the end of the study validate the improvements made and provide the standards for further operations.
Time Measurement also termed work measurement
Cost Measurement (Cost Accounting - Cost Estimating)
Productivity Measurement (Output for each input of various resources, as well as combinations resources)
Process Industrial Engineering - Process Alternatives and Economic Analysis of IE Proposed Alternatives
The possible profitable alternatives to current practice have to be developed based on the knowledge of available tools and their applications, understanding of the requirements of the job being improved and creativity. Creativity is essential in industrial engineering problem solving.
The alternatives have to be subjected to engineering economic analysis for selection as the possible solution.
Up to 60% cycle time reductions on turning using MAXX Machining
4 May 2020
https://www.youtube.com/watch?v=JgURz335Jao
Channel: https://www.youtube.com/channel/UC09R-RDOwz88FqD--3YWmew (MTD CNC)
______________
______________
Up to 60% cycle time reductions on turning using MAXX Machining
4 May 2020
https://www.youtube.com/watch?v=JgURz335Jao
Channel: https://www.youtube.com/channel/UC09R-RDOwz88FqD--3YWmew (MTD CNC)
______________
______________
Illustration: Economic analysis of PCD tool in cutting composite material
Carbon fiber reinforced plastic materials are about 70% lighter than steel and about 40% lighter than aluminum, while costing only about 20% more.
More examples of successful machining time reduction through cutting tool alternatives
Economic - Cost Analysis - Cutting Tool AlternativesMetal Working Fluids - Cutting Fluids - Alternatives
Minimum Quantity Lubrication (MQL) in Automotive Powertrain Machining in Ford
The primary benefits from MQL include cost reduction that includes reduction in energy consumption, improvement in environment, and more effective chip recycling.Ford began investigating alternatives to conventional flood coolant machining technology for aluminum materials in the 1990s through a collaborative project seeking to completely eliminate coolants with an aim towards completely dry machining of aluminum. Many machining operations for ferrous components were already dry. The project was carried out through extensive laboratory trials and a series of small-scale production pilots in early 2000s
Ford began applying MQL to aluminum transmission components in 2005, and by 2008 had over 200 MQL machining centers in operation machining aluminum transmission cases, torque converter housings, and valve bodies at two plants in North America. MQL machining became Ford’s current standard machining method for these components, and is being implemented in new high-volume machining lines globally. Ford began machining aluminum engine heads and cast iron engine blocks in 2011. MQL is now the primarily standard method for machining cast iron engine blocks and aluminum engine blocks and heads. For some specialized operations still wet machining is used . MQL machining modules are being installed in plants in new locations like Brazil and China.
Ford is making effort to extend MQL machining to additional components like CGI engine block machining, thermally sprayed engine bore machining, and aluminum deep hole drilling. There are technical challenges and the research community and engineering community are involved in finding solutions and extend MQL to new areas of application.
Source:
Minimum Quantity Lubrication (MQL) in Automotive Powertrain Machining
Bruce L. Tai, David A. Stephenson, Richard J. Furness, Albert J. Shih
6th CIRP International Conference on High Performance Cutting, HPC2014
Procedia CIRP 14 ( 2014 ) 523 – 528
doi: 10.1016/j.procir.2014.03.044
2019
Cryogenic Machining Technology Used for Cost Reduction
The thru-tool cryogenic machining technology was further developed 5ME LLC under license and it markets it as 5ME® Cryogenic Machining Technology. The system can be used to optimize the performance, sustainability, and part quality of steel, aluminium, and other alloys as well as composite materials. Lockheed Martin is using the cryogenic machining technology to cut titanium parts for the F-35 Joint Strike Fighter, significantly increasing efficiency and lowering costs. Lockheed's Value Engineering team estimates the cost savings/avoidance as over $500 million for the program.
(Cryogenic machining is also a part of Minimum Quantity Lubrication Method)
Machine Shop Industrial Engineering - Operation Process Chart and Flow Process Chart Operations Analysis and Improvement
Material Processing
CNC Working Process | Watch Case making with on Brother Machine CNC | Stainless steel
CAD/CAM SOLUTION, 10 Feb 2021
Brother Machine CNC SPEEDIO S300X2
Material : SUS304/Stainless Steel
https://www.youtube.com/watch?v=AjTcWxl_BLA
Process Planning Introduction
Fredumacation, 18 Oct 2020
https://www.youtube.com/watch?v=sfF1rojlTI0
Jigs and Fixtures: 6 Ways to Improve Production Efficiency with 3D Printing
13 May 2021
https://amfg.ai/2021/05/13/jigs-and-fixtures-6-ways-to-improve-production-efficiency-with-3d-printing/
6 Computer Numerical Control (CNC) Machining Trends for 2021
By Larry Alton
Production and process optimization in CNC manufacturing
https://new.siemens.com/global/en/products/automation/systems/cnc-sinumerik/digitalization/manufacturing.html
Machine shop tool management (May be we can put in warehousing or storage or facilities IE)
https://www.steckermachine.com/blog/managing-machine-shop-tools
Inspection
Renishaw probing increases productivity for machine shop ‘down under’
2 DECEMBER 2021
https://www.pesmedia.com/renishaw-probing-17112021
https://www.heidenhain.us/product/machine-controls-and-touch-probes/
Automotive Supplier Scans Machined Connecting Rods With Diamond Styli for Low Tool Wear.
Silicon nitride stylus tips of micrometers used for scanning were wearing down at a rate of up to one per micrometer per day .
Hearing about new styli with a diamond coating from the field staff at ZEISS Industrial Metrology piqued Pichler’s interest and ordered a loaner stylus – initially the more expensive, solid-diamond version – for one of the two ZEISS PRISMO systems used for the final inspection of connecting rods.
After more than a year, Pichler reports: “We haven’t noticed any wear thus far.” “switching to the diamond-coated and solid-diamond styli has definitely paid off.”
December 17, 2021
https://metrology.news/automotive-supplier-scans-parts-with-diamond-styli/
9/1/2021
Digital Part Inspection Software.
Chick Machine overhauled its decades-old inspection process and landed new clients that have propelled the growth of the company.
https://www.mmsonline.com/articles/digital-part-inspection-software-creates-new-business-opportunities-
Material Handling, Transport and Layout
Why NOW is the Time for Machine Shops to Automate
READY Robotics, 16 Aug 2021
https://www.youtube.com/watch?v=fniNBfHcupE
Raw Material and Parts Storage
Temporary Delays or Delays in Flow
Machine Shop Facilities Industrial Engineering
Industry 4.0 Implementation for Small and Medium-Sized Shops
April 22, 2021
Rizzie: The complexity of Industry 4.0, or the appearance of complexity, is what keeps most people from implementing it. At Sandvik Coromant, instead of thinking of it as an Industry 4.0 problem, we call it the connected machine shop.
https://www.sme.org/technologies/articles/2021/april/industry-4.0-implementation-for-small-and-medium-sized-shops/
Digital Machine Shop Guide
https://cdn.brandfolder.io/GDDASP4K/as/xm6phpcb3hrkgpk79782f6s/LM-0011_Digital_Machine_Shop_Ebook.pdf
Total Productive Maintenance (TPM) Implementation in a Machine Shop: A Case Study
December 2012Procedia Engineering 51(7)
DOI:10.1016/j.proeng.2013.01.084
Conference: Chemical, Civil and Mechanical Engineering Tracks of 3rd Nirma University International Conference on Engineering (NUiCONE2012)Volume: Volume 51, 2013, Pages 592–599
https://www.researchgate.net/publication/236594199_Total_Productive_Maintenance_TPM_Implementation_in_a_Machine_Shop_A_Case_Study
Automated Machine Tool Cell
6/18/2021 |
Automated production line, including its automated storage and retreival system called the Mazatec Smart Manufacturing System, or SMS. Taken together, the system represents an integrated manufacturing cell designed to perform unmanned machining through the use of horizontal machining centers and multitasking machines, along with the material handling technology of Murata Machinery. Murata is best known for its expansive capabilities in material handling, and — in the case of the SMS — its vertically orientated, modular, six-level stocker-type system that includes pallets, automated load stations and high-speed stacker crane.
AUTOMATION
10/7/2021
Buying Robot on Experimental Basis and Using it Profitably for a Machine Tool Tending Job.
Connected Machine Shop - Part 2
IEOR Optimization - IE Statistics Optimization - Six Sigma Method
IEOR - Optimization in Machining Processes
1973
MIT Working Paper
AUTOMATED PLANNING AND OPTIMIZATION OF MACHINING PROCESSES: A SYSTEMS APPROACH
by
Krishna Challa and P. Bruce Berra
November 1973
Automated planning and optimization of machining processes: A systems approach
Krishna Challa and P. Bruce Berra
Computers & Industrial Engineering
Volume 1, Issue 1, 1976, Pages 35-46
More papers given in: Optimization of Machining - Bibliography
IE Statistics Optimization - Six Sigma Method
Taguchi-Based Six Sigma Approach to Optimize Surface Roughness for Milling Processes
Authors: Joseph C. Chen, Sky Chou
2007
This illustration focuses on using Six Sigma methodologies to improve the surface finish of a manufactured part produced by the CNC milling machine and reduce defects produced by the operation. Milling of aluminum is operation. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that lead to reduced variability in surface finish specified by the customer. A L9 orthogonal array was applied in the Taguchi experimental design, The controllable factors are feed rate, depth of cut, and spindle speed, The confirmation run with the optimal parameters determined in the study confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The study confirms that the Taguchi–based six sigma approach can be efficiently used to reduce defects by minimizing variation of the operation and improve the process capability index of the CNC milling process.
https://publications.waset.org/10007983/taguchi-based-six-sigma-approach-to-optimize-surface-roughness-for-milling-processes
More Case Studies on Six Sigma in Machining
Human Effort Engineering in Machine Shop
Ergonomics Applied to CNC Machining
MAY 5, 2014The science of ergonomics involves designing and arranging things so that people can use them as efficiently and easily as possible. When ergonomics is applied to CNC machining the primary focus is on improving productivity and safeguarding the machine operators.
A few examples of how Gosiger Automation builds ergonomics into its systems.
Loading and unloading heavy parts.
See a video of a Gosiger Automation designed cell that uses a Fanuc r-2000 iB robot with a vision system loading and unloading a 100+ pound part delivered to it on an automatic conveyor.
Eliminating repetitive motion.
Even smaller, lighter parts present ergonomic problems best overcome with a robot. A machine operator who is constantly opening and closing the machine tool door, lifting and placing the part into position, then removing the part and loading another is performing repetitive motions that can take their toll on the person’s joints, back and extremities
Seen in a video, how a family of parts can be robotically loaded and unloaded, placed in an inspection fixture, automatically checked using a Renishaw Equator and, using software to analyze the results, make tool offsets all without operator intervention.
Allowing safe access for machine tool maintenance.
https://www.gosiger.com/news/ergonomics-robotic-automation
More on ergonomics
http://www.ilocis.org/documents/chpt29e.htm
https://webstore.ansi.org/industry/ergonomics/machine-ergonomics
http://blog.lenoxtools.com/industrial-metal-cutting/2015/11/20/machine-shops-use-ergonomics-to-increase-productivity-and-reduce-injury/
Applied Industrial Engineering in Machine Shop
Turn Machine Tool Data into Productivity - Industrial Engineering 4.0
MT Analytics offers Industry 4.0 solutions using data Analytics and a hardware Test Lab .
The MT Analytics GmbH is running a component test lab for machine tool and automotive components and provides services to their customers identifying and optimizing dynamical and geometrical problems of discrete manufacturing production systems. Beside MT Analytics GmbH provides Data Analytic Software solutions to optimize given NC Codes and to monitor the quality of parts as well as the condition of all machine tool components. Machine internal data are analyzed in real time by our algorithms that include our expert knowledge and the experience in testing, modeling and optimizing hardware.
Hardware Test Lab
The MT Analytics GmbH is running a Component Test Lab for machine tool and automotive components and provides services to their customers identifying and optimizing dynamical and geometrical problems of discrete manufacturing production systems
Data Analytics
The MT Analytics GmbH provides Data Analytic Software solutions to optimize given NC Codes and to monitor the quality of parts. Machine internal data are analyzed in real time by our algorithms that include our expert knowledge in testing, modeling and optimizing Hardware.
Make Cutting Tool Suppliers Partners in Productivity Improvement
8/14/2009
Tooling Supplier's Productivity Improvement Program (PIP) gives excellent benefits
Even a shop that is committed to continually optimizing processes might struggle with the time and effort required to stay abreast of the latest technology developments. One manufacturer has taken steps toward eliminating this problem by making a cutting tool manufacturer partner in in improvements.
Sandvik's Productivity Improvement Program (PIP). Through PIP, Sandvik technicians collaborate with customer personnel to optimize their manufacturing operations.
https://www.productionmachining.com/articles/tooling-supplier-expertise-lends-competitive-edge
Sandvik's Productivity Improvement Program (PIP). Through PIP, Sandvik technicians collaborate with customer personnel to optimize their manufacturing operations.
https://www.productionmachining.com/articles/tooling-supplier-expertise-lends-competitive-edge
Machine Shop Maintenance
2021
Checklist - Top Preventive Maintenance Tips for Your CNC Machine Tools
by Hwacheon Asia - Aug 6, 2021.
Preventive Maintenance Checklist
(Schedule regular maintenance or servicing sessions, and maintain documentation of service/maintenance. Also, have a specific area for your employees to report issues.)
MECHANICAL SYSTEM
Verify machine level
VMC – verify spindle sweep
Lathe – verify turret square to spindle face
Check lubrication is reaching the spindle
Inspect rotary oil level (mill)
Inspect drive belts
Verify gearbox/motor operation
Inspect tool changer and lubricate
Inspect spindle taper condition (mill)
Inspect toolholders and grease pull studs (mill)
Verify smooth turret indexing (lathe)
LUBRICATION SYSTEM
Inspect filter
Inspect hoses and fittings
Check pump operation / test
Check/adjust pressure, spindle regulator
Inspect system for leaks
Change gearbox oil (lathe only)
Change hydraulic fluid and filter
ELECTRICAL SYSTEM
Clean electrical cabinet
Check incoming voltages
Check DC bus voltage
Inspect connections and terminals
Inspect electrical ground connections
Replace or clean filter fan
Check safety locks
Check axis motors and cables
COOLANT SYSTEM
Inspect coolant hoses
Verify all pump operation
Clean coolant filters
Test and adjust coolant concentration
Inspect coolant tank for sediment
AIR & LUBRICATION SYSTEM
Inspect all lines and hoses
Verify all pump operation
Check incoming air supply
Verify lube/pump operation for axes
MECHANICAL SYSTEM:
Inspect tool holders/grease pull studs.
Inspect the rotary oil level (Mill)
ENCLOSURE/SAFETY:
Inspect safety interlock operation
Inspect windows for damage
Inspect way covers and wipers
PROBE SYSTEM:
Check the probe batteries
Check probe calibration
Monitoring the condition of the spindles: Sensemore uses Trigger device. Trigger sends the measurement order to the sensor by transmitting the 5V signals to the receiver with a code to be returned at the end of each process. Thus, it can monitor the vibrations of a CNC lathe in the grinding wheel spindle at the end of each machining and in a way that the parameters remain the same in every measurement.
Operating the grinding wheel spindle at a constant speed for a short time at the end of each machining and taking vibration measurements during this process will create a correct trend as it is within certain boundary conditions. The code added to the CNC lathe sends a 5V signal to the Sensemore Trigger device after each part is machined. Sensemore Trigger gives the measurement order by triggering the Wired with the signal it receives. The whole process is completed in as little as five seconds and analyzes are performed on the Sensemore cloud application.
Nowadays, maintenance, and quality processes are carried out in an automated manner. . Sensemore, thanks to the portable accelerometers, application-specific hardware, and cloud-based analysis program they developed, offer easier and more reliable automated maintenance and quality control processes.
Troubleshooting CNC Breakdowns and Steps to Avoid Them
March 22, 2021
Industry 4.0 in CNC Machine Monitoring
Machine Shop Industrial Engineering - Bibliography
2019
HOW TO START A CNC SHOP: EVERYTHING YOU NEED TO KNOW
Don Sears, Posted Mar 12, 2019
Improving machining process by College students in their project work on lathes
https://books.google.co.in/books?id=bsqDDwAAQBAJ&pg=PA329#v=onepage&q&f=false
https://www.researchgate.net/publication/330360898_Time_Optimization_Implementation_in_Conventional_Lathe_Machining_Operations
Reconfigurable Manufacturing Systems: From Design to Implementation
Lyes Benyoucef
Springer Nature, 19-Oct-2019 - Technology & Engineering - 250 pages
https://books.google.co.in/books?id=0uK3DwAAQBAJ
2018
https://www.industr.com/en/metal-working-fluid-performance-in-aluminium-high-speed-machining-2351265
2013
Questions from an Industrial Engineer in an Automotive Machine-Shop
I received the following questions from an Industrial Engineer (IE) who has recently moved from vehicle assembly to the machining of car engine parts, blocks, heads, crankshafts, etc., activities that all new to him:
Any reading material you would recommend?
Is takt based off the slowest machine or the machine in the line that makes the least parts?
Knowing cycle times and uptimes of a 30 machine line how do you calculate system uptime?
Should there be more overspeed for machines at the beginning half of the machine line?
Process Planning Optimization in Reconfigurable Manufacturing Systems
By Farayi Musharavati
2008
https://books.google.co.in/books?id=ab6iQ-4SG5wC&printsec=frontcover#v=onepage&q&f=false
1996
Introduction to Machining Science
Prof G.K. Lal
IIT Kanpur
https://books.google.co.in/books?id=MTiwBJ5VbtYC&printsec=frontcover#v=onepage&q&f=false
1973
Proceedings of the Fourteenth International Machine Tool Design and Research Conference
S. A. Tobias
Macmillan International Higher Education, 1973 - Engineering - 841 pages
https://books.google.co.in/books?id=bFVdDwAAQBAJ
Updated 29.12.2023, 19.4.2022, 8.1.2022, 17.12.2021, 8.5.2021,28 May 2020, 17 May 2020, 2 May 2020
First published 27 April 2020
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