Speaking of Precision Blog

Speaking of Precision

Speaking of Precision is a knowledge preservation and thought leadership blog covering the precision machining industry, its materials and services. With over 36 years of hands on experience in steelmaking, manufacturing, quality, and management, Miles Free (Milo) Director of Industry Research and Technology at PMPA helps answer "How?" "With what?" and occasionally "Really?"

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It's Not One Thing

Posted September 01, 2015 1:00 PM by Milo
Pathfinder Tags: business machining tips

5 Lessons I learned about our machining business.

Last month I was privileged to attend Horn Technology Days.

Here are some 5 6 lessons learned.

Lesson Number 1- It's not one thing.

  • There is no magic bullet.
  • There is no miracle pill.
  • Machining is a system.
  • Understand the system, and address system weaknesses.

Stop looking for magic answers. There is seldom a single change that you can make that will single -handedly optimize your process. You must consider the entire system. I took in every technical session while I was there. I expected to be told that "whatever it is I'm showing you" is the answer to your machining problems.

I was not told that at all. In all of the sessions, the focus was on understanding and optimizing and understanding the interactions of the system and its components. Very refreshing.

Lesson Number 2- In our business, success is defined by sustainability, not lowest price.

By sustainability, I do not mean Greenwashing.

Sustainability is not about Greenwashing!

To be sustainable, a company must learn to solve problems.

Problems unsolved have the potential to bring your company down.

How to become more sustainable:

  • Solve problems first.
  • Solve the problem for good.
  • Understand that the lowest cost over the long term is not the lowest price in the short term.
  • Spend less time on maintenance by planning it.
  • Spend more time on production.
  • Spend more time on innovation.

This is why we have root cause analysis. We should only have to solve a problem once. Assure organizational learning takes place. And move forward.

Lesson Number 3- Pay attention to energy

This one was a complete surprise. Who knew that 37% of Machine tool energy consumption is related to coolant and lubricant?

  • Through tool coolant typically runs at a rate of about 1 liter per minute (About a quart here in the US)
  • Traditional flood coolant is typically 18 liters per minute. (That's about a 5 gallon bucket in imperial units.)
  • And the through tool coolant is applied exactly where it is needed.

I'm not quite convinced that MQL is the answer for production machining, but I saw some demonstrations that continue to make me think.

On another note, typically utilities run from 6-10% of sales dollars in our shops. we've seen estimates that shop lighting can run as much as 37% of the electrical consumption in Warehouses and light manufacturing shops. Even if you cut that in half, it is probably wise to evaluate your current shop lighting. We can talk about compressed air another time. If you hear compressed air in your shop- you are listening to dollars floating away.

Lesson Number 4- Conventional milling = Conventional rubbing

Your daddy's way of milling is no longer preferred today.

All of the programs on milling at Horn showed climb milling as the preferred practice. I'm not going to pretend expertise here- just that what I thought I knew is no longer what I think I ought to know in regards to cutter rotation and material feed. Climb milling is the preferred way in modern shops today.

Lesson Number 5- Be optimistic.

HORN is expanding again. Another new building was being built just down the road.

New building on Dusslinger Way

Why be optimistic? How can you be optimistic?

  • It is easy to be optimistic if you are a private company.
  • If you believe in continuous improvement, then you want tomorrow to be better than today.
  • Today is today, but our way is the future. Our way is going forward.
  • Do it today. For tomorrow.

Can't argue with that. That is why HORN has a full class of apprentices in development.

How about you?

Bonus Lesson Number 6- "The Best People are the Basis of the Future"

Lothar Horn

Lothar Horn shared that thought with me in a private conversation. It really fit hand in glove with HORN's optimistic approach to the future. By training the people and making available opportunities to learn and grow, the company is preparing their team for an anticipated, but not yet understood future.

"There is a continuous demand to upgrade our tools. We can only meet that demand by upgrading the skills of our workforce and the technology they apply."

When that future arrives, they know that they have done their best to be prepared for that day and its challenges.

That future will arrive. It arrives every day. What have you done to prepare your shop for the future that will soon arrive?

NoMagicBullet


Editor's Note: CR4 would like to thank Milo for sharing this blog entry, which you can also read here.

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#1

Re: It's Not One Thing

09/02/2015 6:26 AM

Interesting entry's Milo, Can you give more details as far as climb milling is the preferred practice?

I always felt that it's depended upon the process that dictates the milling.

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Re: It's Not One Thing

09/02/2015 9:45 AM

Climb milling requires less power, and can run faster than conventional milling on CNC machines. It also results in a smoother surface finish, and may not require a finish pass. On some manual machines, conventional milling may still be the preferred method. I'm sure Milo could provide some links that explain the preferences far better than I can.

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Re: It's Not One Thing

09/02/2015 5:11 PM

True. But for heavy cuts this requires a rigid machine. You are not going to do this on your typical Bridgeport

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