Define: The number of setups & the associated setup time is hurting our ability to be competitive. Creating a mill fixture for every part is capital intensive and adds to our non-recurring costs. Non-recurring costs are too high, especially since we generally don't get paid for those costs up front, rather they must be amortized over the run of production parts.
Measure: Moving clamps around and stopping the machine to do it cost too much. Counter-bored bolts are always in the way of the process and require more setups to get around them especially in mult-axis machining. Manufacturing a fixture plate for every new part requires design, program and fab time.
Analyze: By using picture frame machining concepts and tabbing schemes it was possible to eliminate the use of clamps. By establishing a standardized mill fixture plate it was possible to eliminate design, program and fab time. It was also possible to eliminate producing a mill fixture for every new part.
Improve: Implement standardized workholding techniques and eliminate duplicate milling fixtures by incorporating modular fixturing. Convert tooling to Invert-A-Bolt™ Universal Common Modular fixtures for horizontal machining cells. Use Invert-A-Bolt™ fasteners to replace bolts and clamps for vertical machining.
Control: Establish standardized workholding procedures. Train operators, CNC programmers and tool designers to "think Lean" and maximize the benefits of using Invert-A-Bolt™ fasteners for workholding. |
Define: The efficiency of our high-speed machines is reduced due to vibration and un-stable setups.
Measure: We are running our spindles at 60% of possible due to vibration in the setup.
Analyze: By getting the holding power of our clamps closer to the fixture plate we can improve the stability of the setup. The taller the clamp setup, the more vibration we encounter.
Improve: Replace clamps with Invert-A-Bolt™ fasteners which are contained in the fixture plate and hold the part as close to the base as possible.
Control: Establish standardized workholding procedures. Train operators, CNC programmers and tool designers to maximize the benefits whereever possible of using Invert-A-Bolt™ fasteners to create stability in the setup. |
