Process Improvements for Establishing CMMI Certification ...
Process Improvements[1]
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Process ImprovementsProcess Improvements
Steve TaylorFMF Supervisor
VCN 40T SpindleVCN 40T Spindle• Deep Bore Process exceeded Deep Bore Process exceeded 1hr 10 min1hr 10 min..• Chip Control issues.Chip Control issues.• Machine load concerns for production demandsMachine load concerns for production demands..• Reduced cycle time by 81%. Reduced cycle time by 81%. • New cycle time New cycle time 22 min22 min• Changed program to optimize tooling.Changed program to optimize tooling.• Changed depth/cut and speed/feed ratio for better tool life and Changed depth/cut and speed/feed ratio for better tool life and
chip control.chip control.• Replaced Sandvik with SECO inserts.Replaced Sandvik with SECO inserts.
SECO - CNMG 432 TP1500SECO - CNMG 432 TP1500
SECO - 32.51 TP1500SECO - 32.51 TP1500
200/250 STD Headstock200/250 STD Headstock• Cycle time for bore application Cycle time for bore application 60min60min..• Manpower could not keep up with demand.Manpower could not keep up with demand.• High Level of reported MDR’sHigh Level of reported MDR’s• Reduced cycle time by 50%. New cycle Reduced cycle time by 50%. New cycle
30min30min• Additional manpower eliminated for current Additional manpower eliminated for current
machine schedule.machine schedule.• One and done conceptOne and done concept• Implemented SECO boring technology.Implemented SECO boring technology.
300/350 STD Headstock300/350 STD Headstock• Cycle time for Headstock application Cycle time for Headstock application
180min180min..• Manpower could not keep up with demand.Manpower could not keep up with demand.• High Level of reported MDR’sHigh Level of reported MDR’s• Reduced cycle time by 50%. New cycle Reduced cycle time by 50%. New cycle 90min90min• Additional manpower eliminated for current Additional manpower eliminated for current
machine schedule.machine schedule.• One and done conceptOne and done concept• Implemented SECO boring technology.Implemented SECO boring technology.
VCN Clamp CylinderVCN Clamp Cylinder• Cycle time Cycle time 1.8hrs1.8hrs• Long turn aroundLong turn around• High production partHigh production part
• Reduced cycle time by 50%.Reduced cycle time by 50%.• New cycle time New cycle time 50min50min..• Adjusted program to optimize current tooling.Adjusted program to optimize current tooling.• Implemented Ceramic technology from Sandvik.Implemented Ceramic technology from Sandvik.
200/250 Rotor Sleeve200/250 Rotor Sleeve• Cycle time Cycle time 1.2 hrs1.2 hrs• Undesirable tool lifeUndesirable tool life• Chip control issuesChip control issues• Man operation due to poor processMan operation due to poor process• Reduced cycle time by 50%. Reduced cycle time by 50%. • New cycle time New cycle time 40min40min..• Implemented SECO insert. Implemented SECO insert. CNMG 432 TP1500CNMG 432 TP1500• Changed cutting data to control chip breakage Changed cutting data to control chip breakage
and tool wear.and tool wear.
STD 200/400 TurretsSTD 200/400 Turrets
3.4
5.3
3
4.7
0
1
2
3
4
5
6
200 Std 400 Std
Old New
Old ProcessOld Process New ProcessNew Process
Cutter - RA245-152 Cutter - RA245-152 Insert - R245-18T6Insert - R245-18T6Speed - 750RPMSpeed - 750RPMFeed - .3Feed - .3
Cutter - RA365-101Cutter - RA365-101Insert - R365-1505Insert - R365-1505Speed - 4000RPMSpeed - 4000RPMFeed - 1.4Feed - 1.4
Old New
12% Reduction12% Reduction
Semi/Finish Tooling for HeadstockSemi/Finish Tooling for Headstock
0
0.5
1
1.5
2
2.5
3
Cycle Time
Old
New
Cutter - R220-100-63 Cutter - R220-100-63 Insert - TNGN 22 PCBNInsert - TNGN 22 PCBNSpeed - 6000RPMSpeed - 6000RPMFeed - .6 PER REVFeed - .6 PER REV
Cutter - R220.96-100 Cutter - R220.96-100 Insert - XNEX 080608TRInsert - XNEX 080608TRSpeed - 1000RPMSpeed - 1000RPMFeed - 1.0 PER REVFeed - 1.0 PER REV
CYCLE TIMECYCLE TIMEOLD - 2.35 HRSOLD - 2.35 HRSNEW - 1.4 HRSNEW - 1.4 HRS
48% REDUCTION48% REDUCTION
Semi-Finish
Finish
MU-8800
Cutter - R290-100-63 Cutter - R290-100-63 Insert - R290 -12 03 6090Insert - R290 -12 03 6090Speed - 1000RPMSpeed - 1000RPMFeed - 1.0 PER REVFeed - 1.0 PER REV
0
50
100
150
200
250
300
510 Head 400 Car 450 Head
Old
New23%
44% 40%