For one automotive
mold maker, improved cycle times on EDM machining unlocked the door to further growth.
Slow manufacturing processes can spell sudden death for tool builders in a competitive field such as automotive manufacturers, where yesterday's technology is no match for today's increasingly high demands. To ensure success, shops are relying on new ways to improve cycle times for better productivity and higher work capacity. As more and more mold and die manufacturers adopt this philosophy, shop floors are taking on the appearance of carefully orchestrated showrooms for the latest technologies, producing more work in less time.
Joe Lockman, manufacturing manager at J.S. Die & Mold in Grand Rapids, Mich., knows firsthand the importance of keeping a shop floor technologically current. With modern technology improving processes, customer demands at J.S. Die & Mold are greater than ever. "These days, customers expect turnaround on a tool to be six or eight weeks, whereas a year ago they might have given us fourteen or fifteen," Lockman says.
"Every time we've updated our equipment, we have been able to grow our capabilities to handle larger tools and bigger jobs," Lockman explains. "And, it seems like every time you buy something bigger, the next thing you know the customer comes along with an even bigger job they want you to quote." Obviously, getting work for big jobs is an ideal problem to have. And, as Lockman tells it, the solution lies in outfitting your floor with the proper equipment.
Lockman is part of the team that determines new equipment to purchase for the J.S. Die & Mold floor. He attributes the increasing demand for better technology to changing customer needs. "Our customers now have more immediate needs for advanced tooling, and the only way to keep up with that demand is to update your equipment. There is no way around it. You've got to buy the newer equipment to keep up with the world out there and build their tools."
SPEED AND QUALITY
"When we buy new equipment, we choose a given machine for two reasons: improved cycle times and the overall quality of the equipment, which determines the quality of the tools you produce," says Lockman. He estimates J.S. Die & Mold saves 50 to 70 percent or more in cycle time with its improved processes and new EDM technology. "You know, you keep hours off as much as you can-a lot of this work runs unattended. Time savings is the name of the game; it is our goal."
J.S. Die & Mold has been in business for 18 years. The company specializes in plastic injection molds for the automotive industry. It employs more than 50 people who work on the floor and in the office, building tools for a number of customers in the Grand Rapids area, including Johnson Controls and Summit Polymers, as well as some smaller automotive companies. J.S. Die & Mold also occasionally does appliance work and has created tools for companies like Frigidaire, but the majority of their work is automotive.
The EDNC85 has had a major impact on J.S. Die & Mold's productivity. Before purchasing the machine, burning one repetition used to require using three or four electrodes. Today, it takes only two. Says Lockman, "A job that might have taken you eight hours before only takes an hour now. There's just no comparison."
Lockman and his colleagues at J.S. Die & Mold justify equipment purchases in terms of resulting productivity improvements. Says Lockman, "The bottom line is you've got to turn work around fast." Time savings justify expenditures for J.S. Die & Mold. Lockman counters, "You can buy some cheaper piece of machinery, but it's not going to have the number of tool changes on it that we like." Faster equipment means greater work capacity and, as Lockman puts it, "When you do get more work from the customer, the machine pays for itself."
EFFICIENCY AND RELIABILITY
The EDNC85 from Makino was created for enhanced accuracy and reliability in a compact, space-saving design. It provides high positioning accuracy and repeatability for superior machining quality, and the pendant control panel and sliding work tank help boost work efficiency. Because of its integrated design and power supply, less floor space is required for installation, and the power supply is fully enclosed for high reliability.
Its larger tank size handles bigger work pieces accurately, and the rib head attachment makes small electrode machining possible in a big environment. In fact, the heavy-duty EDNC85 can produce deep ribs as faster or even faster than the smallest Ram EDM machines on the market, and jump speeds of 40 mm/minute eliminate any need for flushing and provide unique finishes from top to bottom on all side walls.
The EDNC85 features a "drop tank" design, heavy-duty construction and a three-axis head, all of which result in better, faster machining. The EDNC85 machines 20 to 30 percent faster than manual EDM machines, all while producing superior feature definition and surface finishes that reduce polishing times by 50 percent or more.
SUPERIOR SERVICE, BETTER RESULTS
The faster equipment means J.S. Die & Mold's customers have more immediate expectations, and faster lead times are good for business. As Lockman puts it, "One thing is for certain… we are really busy."
Over the last three years, they have purchased several new Makino machines. Their latest acquisition is the EDNC156, to which Lockman attributes a great deal of J.S. Die & Mold's increased capability. The competitive advantage, in Lockman's view, is tremendous. "It has a 32-station tool changer, which brings us several machining options." With marked enthusiasm, he adds, "We have some old manual EDM machines, and there is absolutely no comparison between them."
One key benefit to the new machine Lockman's found is the ability to run unattended. "You can be gone all weekend, running the machine unattended, and the job's done when you come in on Monday." More specifically, he notes, "One likely scenario is that we would have a guy come in on a Saturday for about an hour to change electrodes, then again Sunday, and when we come in Monday the tool would be about 90 percent complete."
Lockman cites Makino's superior service as yet another reason he chooses Makino equipment. "They are very good people to deal with," he says. "If you ever have problems, they are right there. You call them up, and they call you back the same day. That's service."
For now, the EDNC machines more than satisfy J.S. Die & Mold's needs. Lockman adds the Makino machine's are sure to take care of J.S. Die & Mold for a long time to come.