The MV-R series of wire-EDM machines are designed for high performance, according to Mitsubishi officials, with the latest models making use of IoT-augmented D-Cubes control that promises improved accuracy. Other machine features include new technology for automatic wire feeding, a next-generation drive system and user-friendly human-machine interface. Such advancements have paid dividends for Dies Plus.

For example, “about a year ago, a customer was looking for small carbide tools measuring only about 2.5 in. thick, with tiny comb-like teeth,” recalls Dombrowski. “These parts challenged us, and we reached out to MC Machinery and Mitsubishi for an equipment solution. We put our heads together and figured out solutions for workholding and machining, and ended up making great parts for that customer. We appreciate such support as well as the fact that MC Machinery is not far from our location—service and support always are there.”

Tackle Tight Tolerances, Free Team for Other Challenges

This becomes even more important for the wire-EDM department at Dies Plus, which often faces challenges given the abundance of high-speed-stamping applications.

“Tooling for high-speed stamping has some tight tolerances,” says Dombrowski. “But the Mitsubishi wire-EDM machines have no problems meeting those tolerances. I’ve had the Otto toolroom manager come over and tell us that he put components together with perfect fits and no hiccups. To know what we’re getting out of those wire-EDM machines on a consistent basis is huge for us. I’ve been in this business for 30 yr., and wire-EDM technology has come a long way from when I first started, such as with automatic wire threading. I started on a manual machine and remember having to thread the wire myself. Now, even if the wire breaks, the machines quickly get up and running again. I get what these new features mean.”

What they mean for Dombrowski and his wire-EDM teammates is the opportunity to apply their knowledge instead of slogging along doing mundane work.

“We certainly do still have challenges, but being in this environment with state-of-the-art technology and high machine performance, challenges are the fun part,” Dombrowski says. “We can be creative and use our experience in meeting the challenges. Overcoming those and creating good tooling that makes good parts makes it worth it. Anyone can do the every-day stuff, but the challenging work makes this job fun.”

People Plus Technology Equals Success

Just as with any technology, the wire-EDM machines under roof at Dies Plus only function at their best due to those manning them, Dombrowski stresses.

“We can have all of the technology in the world, but it is about the people,” he says. “This requires the right people, and Otto and Dies Plus do this very well. We began an apprenticeship program in 2018 that has graduated more than 20 apprentices. We have eight in the program now—CNC machining, diemaking, etc. Otto and Dies Plus have gone out of their way to make sure that we have young people in here that are interested in this type of work and want to continue in it as a career.”

MC Machinery adds to the knowledge base at Dies Plus through multi-day training for machine operators. Such training and experience combined with machine capabilities surely has boosted productivity, which brings another challenge: keeping the machines fed.

“We must make sure to have enough workflow going through all of these machines,” Dombrowski says. “We might have nine or 10 die blocks a day going through each of our nine wire-EDM machines. These machines eat up every one of those blocks, and we have to keep the tool materials coming in the door and to the machines.”

Remote Monitoring Aids Uptime

With such demand, the machines must remain online. A big help, according to Dombrowski: Remote 360 from MC Machinery. The cloud-based mobile application—also available for laser cutting and sinker-EDM machines—remotely monitors equipment, predicts maintenance needs, and provides data such as run, stop and idle time to help diagnose and fix issues. And, the Remote 360 app alerts offsite personnel of urgent issues. 

“For us, Remote 360 tracks wire usage and wire breaks, length of jobs, and more,” says Dombrowski. “We can go back into the application’s library to find out all about a particular job, and monitor machines on our phones. We don’t have to run in here three times over the weekend to monitor an important job. Remote 360 has saved us numerous times.”  MF

See also: MC Machinery Systems, Mitsubishi Electric US, Inc.

Technologies: Tooling

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