Efficiency, Cost Savings and More Competitive Quotes

Using Cimatron Die Design for blank development and the strip layout, Rezler says that, “complex strips that used to take us 3 to 4 days to lay out now take 3 to 4 hr. Simpler strips can take as little as 10 to 15 min.”
Rezler also finds that the benefits of the software’s quick blank-development and forming-analysis capabilities really pay off in his quoting work. “The forming analyses highlight any hot spots, wrinkling, splits and other areas of potential difficulties,” he says. “It saves a lot of time and eliminates the guesswork. Most importantly, it gives me the confidence to quote exactly what needs to be done rather than over-quote to protect against the unexpected, like we used to do. It allows us to come up with more competitive quotes.”

On the shop floor, Rezmin has been able to eliminate much of the time-consuming and expensive manual plate work. “We used to do a lot of work with manual radial drills, laying out and transferring screw holes, spring pockets, dowels, keys, etc. Now all of these procedures are designed into the solid model and programmed directly to the CNC machine, which routinely runs some parts in one setup that used to require two or three setups. Labor hours on manual machining processes have been dramatically reduced.”

Rezmin’s programmers take advantage of the Cimatron auto drill function to define sequences for different types of holes and pockets. “The ability to define templates for cutting procedures is a huge timesaver,” adds Rezler.

Lights Out

Archived Webinar Embellishes the Story

Mr. Rezler recently participated in a webinar hosted by MetalForming and PMA, where he speaks eloquently about his firm’s ability to compete with low-cost countries. To listen in, access the archived webinar at www.metalformingmagazine.com—click on the Multimedia Center link.

Article provided by Cimatron Technologies, Inc., Novi, MI: 248/596-9700; www.cimatrontech.com.

Driving to squeeze every hour of productivity from its machines, Rezmin runs two shifts during the day and also runs a third untended lights-out shift. “Cimatron is able to define the tools as well as the holders and spindles, so tool changes can be done without operator intervention,” explains Rezler. “Thanks to the automatic gouge gap checking, cutter paths are guaranteed not to crash. It makes the operators comfortable walking a and setting up lights-out machining.”

Using the same software for design and machining is another big timesaver for Rezmin. “We don’t need to go through the cumbersome process of translation,” says Rezler. “It has eliminated all issues of miscommunication and missing or corrupt information. The CNC operators pull their data right from the design. Whenever we experience a design change, the operators als have the most current information—no need to worry about the integrity of the data.”

The View from the Floor

Finally, the Cimatron viewer seats on the shop floor provide machine operators with direct access to the part data, so they can pull sizes and dimensions directly from the 3D assembly. As a result, detail prints are no longer needed for most parts and components, helping Rezmin run a greener and leaner shop floor operation. 

“Overall, we are 25 to 30 percent more efficient than we used to be,” concludes Rezler. MF

Industry-Related Terms: Blank, Center, CNC, Die, Form, Forming, Gouge, Model, NC, Plate, Run, Strips, Tapping, Wrinkling
View Glossary of Metalforming Terms

 

See also: 3D Systems/Cimatron Software

Technologies: Tooling

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