BIT PLANT CNC CYCLE TIME IMPROVEMENT Ed Lusk 06/28/2016
CNC CYCLE TIME IMPROVEMENT Problem statement: Current tooling, inserts, holding capability and programs on our CNC’s do not reflect a cutting edge in the marketplace for the newly acquired products from Wuxi, China manufacturing plant. Background / Current conditions: In 2014 the decision was made to move the Production Facility from China to North Bay. The lead time in China was 21 to 35 days to manufacture the various products. Our customers expect lead times between 3 to 5 days. The impact of this problem results in our incapacity to have competitive lead times with our competition, the loss of orders and loss of market share.
CNC CYCLE TIME IMPROVEMENT Roots causes Machine parameters Labor force Not comfortable Feed and speed Rigidity New products Programs Training Improve productivity and repeatability Dedication, minimize setup Technology Quick change Different CNC Speed on inserts Old CNC Coolant thru tooling Labor force Machine parameters
CNC CYCLE TIME IMPROVEMENT Our goal: To reduce the machining process cycle-time by 25% in a 6 month period, ending October 2016.
PLAN – DO- CHECK (FOR STUDY) – ACT (PDSA) Countermeasures (Plan) – 4 factors to enhance cycle times Old tool holders with external cooling to new tooling with coolant running through bars for better cooling on insert point of contact. Better grades of roughing and finishing inserts for higher machining speeds and cutting feeds for greater productivity. Improved product machining programs to include greater speeds and feeds to decrease cycle machining time and machining capacity. Upgrade CNC product clamping – from 3 jaw product holding to a more robust collet system.
IMPLEMENTATION (DO) Current program cycle time / minutes 30 25 20 15 10 5 0 CBT IMP 76T6 8.21 NW Casing shoe 5.2 NO2 Bit HO Bit Geobor FD Geobor SS CBT 76T2 HWT Casing NO Bit TNW Bit HO3 Bit Cycle Times 3.4 4.23 28.54 27.6 6.21 13.55 3.34 5.35 8.42
RESULTS / CONCLUSIONS (STUDY) Updated cycle time / minutes 30 25 20 15 10 5 0 NO2 Bit HO Bit Geobor FD Geobor SS CBT 76T2 HWT Casing shoe CBT IMP 76T6 NO Bit TNW Bit HO3 Bit NW Casing Shoe Previous cycle Updated cylce
PLAN – DO- CHECK (FOR STUDY) – ACT (PDSA) Results of implementation Newer grades of turning inserts for higher speed and cutting feed capability. Updated programs resulting in an average of 51% reduction in cycle times New tooling with flow through coolant onto insert point of contact. New collet to hold the product secure for machining of product.
FOLLOW-UP ACTIONS (ACT) “New” Continuous Improvement Board: for continual generation and implementation involving new ideas for improvements of product, consistency, capacity, repeatability & sustainability. New ideas In process Completed
COMMITTED TO SUSTAINABLE PRODUCTIVITY.