With the new advances in CNC technology, now is a great time for machine shops
to critically take a look at processes and see areas for improvement. Many
operations overlook evaluating their CNC equipment and how it can contribute
to overall equipment effectiveness. Below are ten key steps manufacturers can
take to boost their efficiency.
1. Add Automation:
Automation can increase production and efficiency no matter the type or
complexity of the manufactured products. Even though many different industries
are seeing the benefits of adding automation to their operations, smaller
machine shops have been reluctant to make an initial investment in robotics.
However, with the growing availability and affordability of flexible
collaborative robotics, or
cobots, more
operations are becoming interested in this type of automation, especially for
high-mix, low-volume applications. Labor and sometimes space can be at a
premium in many smaller facilities, so machine shops should look for machine
tending robots or cobots that are reliable, easy to integrate and have a
smaller footprint. Adding cobots, robots and software that have the ability to
be easily connected can improve throughput as well as overall equipment
effectiveness.
2. Use the Latest and Greatest Machining Practices and Technology:
Many manufacturers leave performance on the table due to outdated processes
and programming. Are you getting the most out of your machining? Now’s the
time to look at the advantages in new CNC technology. Because new controls
have greater processing speeds and can implement advanced algorithms, they can
do a lot more for your operations.
3. Digitize the Machining Process:
New digital tools are breathing innovation and life into increasingly more
areas of manufacturing, including the application of digital twins in the
machining industry. Digital twins provide virtualization of the machine,
control and manufacturing process. Digitalizing traditional manufacturing
processes have the potential to make operations more efficient by proving out
production processes in the virtual world. That means less waste, more
efficiency and a more equipped workforce.
4. Upgrade with a CNC Retrofit:
Do you have legacy equipment? Running older CNC machines can have hidden
costs, such as taking the time to source and find older replacement parts
leading to significantly longer total downtime and production losses. However,
scrapping old equipment and starting new might be too expensive, especially
when factoring in tooling, fixturing, rigging and foundation costs. Plus, new
machines may require more training for staff. A
CNC retrofit, which replaces
older CNC systems with new controls,
industrial PCs,
servos and cables, can speed up
processing and reduce cycle time by as much as 50 percent.
5. Refresh the CNC Interface:
The latest
CNC interfaces have become
simpler and more intuitive, so they are easier to use than ever before. With
graphical designs that provide a similar look and feel to a smartphone, new
high-definition displays and touchscreens can clearly show specific workpiece
areas. This provides full visibility and zoom-in/zoom-out capabilities during
machining, which can help operators verify the machining program.
6. Take Advantage of IoT:
If shopfloors are not yet taking advantage of IoT information, they need to
make that a priority. In today’s business climate, real-time operational floor
insight to enable data-driven decisions is critical. Software solutions exist
to suit every manufacturer, whether you operate dozens of multi-axis machines
or run a small job shop. To get real insight into operational problems,
IoT software is key to effectively
monitoring, collecting and analyzing operational data. With this type of
software, users can view a snapshot of their operations remotely. For
maintenance departments, the performance of the CNC’s components can be easily
monitored and many systems send real-time alerts if a component is reaching
the end of its expected lifespan. To further assist maintenance tasks, alerts
can be linked to operation manuals that list detailed repair instructions.
7. Prepare for 5-axis Machining:
Investment in
5-axis machining is predicted
to ramp up as more operations produce more complex parts used in high-tech
industries, such as aerospace and medical device production. From the CNC
perspective, machine tools that have powerful controls with advanced functions
for optimal 5-axis toolpaths can significantly help shops get the most out of
their 5-axis machining. While it’s possible to do the required 5-axis
machining with legacy controls or functions, the workflow is significantly
simplified with modern CNC functionality.
8. Training the Future Workforce:
As 5-axis machine tools use increases, the demand for 5-axis operators will
exponentially grow. Training new or existing workers in an effective and
innovative way will be key to bridging this skills gap. To help solve this
shortage, 5-axis training simulation software can allow users to learn how to
setup and operate advanced 5-axis milling machines. Simulation training can
offer an immersive environment to practice and understand advanced machining
techniques. Since 5-axis machining involves more complex machine setups,
simulation software enables users to experiment with and prove out the machine
setup and/or part program before modifying the actual machine.
9. Invest in Tested Motors:
Having reliable and powerful motors are at the very heart of every
manufacturing facility. To help determine a quality motor before purchasing,
it is important to know how they have been tested and what environments and
conditions they are designed to work under. Some manufacturers test their
motors for resistance to: vibration, electrical interference, leaking while
submerged, mist penetration, extreme temperatures and premature wear. Motor
OEMs with high standards will reject designs that can’t hold up to an
equivalent of 30 years of use in each of those tests. For motors to be
successful in manufacturing, motors must undergo the most rigorous of testing
to ensure they can standup to harsh environments and tough cleaning
procedures. Making sure your motor manufacturer has put its designs under a
certain amount of torture testing can make or break an investment.
10. Form Relationships with Trusted Partners:
Whether you are starting an IoT, automation, OEE or another business journey
endeavor, be sure the solutions you pick are from a well-known and respected
provider. Having a partner that will work with you for the long haul is one of
the most important decisions you can make. No matter the technology offered,
if a company can’t form a relationship that will last a number of years, or
worst, not be in existence in the next year or two, then the project can be
doomed to fail. Product cycles and development of new products can take a
significant amount of time, so choosing a company with a solid reputation and
global support and service is key.