Machine Setup

[Mr.ZX]

Yeah I agree with the tool shadow boards, and everything in easy reach of the machine. The biggest time waster is looking for “stuff”. We have the 5s system set up and everything has a place, even the brooms and dust pans. This saves SO MUCH TIME, you know where to go for tools, cleaning stuff and so on. I did not set up my vises with pins, I use keys in the t-slots, and have made several tools to help the operators in set up time. I do not like the idea of dedicated tools to a specific job, this is very expensive to inventory and control. I have some Hout tool cabinets that all of our tools are stored in, and it is cleaned and inventoried on a regular basis. I cannot stress how important cleanliness and organization is. Throw away any crap you do not use! I measure my tool lengths in the machine, we do not have a tool pre-setter. I made some tool setting post that are mounted to the machine table to measure all tools on. I do not like the "top of part “ method to measure tools, sloppy and inaccurate. I do keep some common tools in tool holders, a few end mills, and face cutters, but all else is torn down and put away after each job. I know of several shops that have created “grid plates” but never use them to their full potential. Drilled grid plates become a cleaning nightmare after a while (blowing all the crap out of the holes). We also use ball locks on a few of our machines, they work well, because we set our fixtures and parts in place when programming. Build fixtures that are easy to renew, and easy to build, keep in mind all GDT requirements when designing the fixture, and identify the fixture for future reference, have a designated area for them. I read a study several years ago, in Japan they follow the 5S approach, and can account for every minute a machine is being utilized. This saves time and generates money by knowing what the current shop capabilities are at any given time.

Also if you do not have a good file system, you are losing time. You should have a sold, easy to use filing system on your computer network, keep all programs documents in the same place under the part number. Make set-up sheets that are clear and concise so the set up guy does not need to come and ask questions. Remember every step he takes into your area, or office is wasted time and money, maybe a dime a step if you please. Machinist are not keen on putting things away, you will have to teach them to do it. When they learn to put everything away in its proper place, they will see the advantages. As a programmer you need to be the lead by example guy.

 

KISS Keep It Simple Stupid, don’t mean you are stupid, it is just an old Acronym……….