Page 24 - MetalForming February 2011

Process Integration
focus in determining the efficiency of a system is the speed at which a part is produced, we may find ourselves only adding to our inability to increase prof- itability. Recently, I toured a sheetmet- al-fabricating shop with a fully auto- mated system that spits out parts like Bayer does aspirin. It was impressive to see. The rationale for acquiring the sys- tem: speed and efficiency, and the labor savings from the automation. As we
waded through a warehouse full of work in process, the owner noted how pleased he was with his new system, and then said: “Now if I can just make money.”
The acquisition of this new system addressed the two smallest portions of elapsed time for processing any part—setup and process times. And since queue and wait times consume the majority of elapsed time, by inte- grating processes we can address the
largest segment of available time. In the end, this company may have been better off to have allocated valuable resources to more flexible systems that can pace the shop and reduce WIP.
Fewer Touches, More Savings
Fabricators that invest in process inte- gration realize cost savings by reducing post-operational costs. The goal is to reduce the amount of touches to a work- piece, and the related time consumed, for setup, processing, queue and wait.
New punch-press technology com- bined with new tooling technology can allow fabricators to produce parts with offsets, ribs, louvers and flanges formed in process, as well as straightline and contour shearing. Fabricators can even use a deburring tool in their CNC punch press that eliminates burrs in process.
Another recent innovation from providers of punch-press tooling are tools capable of performing in-process bending by forming C, Z and L bends up to 0.79 in. Difficult tabs on the interior of a part or smaller flanges can be formed in-process, eliminating the need for additional press-brake operations.
Another perk of improved ram con- trol from machine vendors: part mark- ing, with either dot-matrix or scribing tools. Parts are marked or labeled by the ram coming down under precise con- trol, until the tool penetrates the sur- face of the material by about 0.002 in., combined with precision sheet posi- tioning on the work table. This process can eliminate many post-process part- marking operations.
Tapping is another typical post- process task that can be accomplished on a CNC punch press, using various options. Available to fabricators is an in-turret tapping tool that taps 12-24 through 3⁄8 or M6 - M10 at speeds to 180 holes/min. This can reduce the cost of a tapped hole to as low as $0.01/hole. Other tapping options include four- and eight-station tapping units that mount right onto the frame of the machine, offering greater flexibility with multiple resident tools. Once again, by utilizing in-process tapping, post-operation costs are reduced. MF
connect everywhere
Network your factories and offices with SmartPAC 2 and LETS (Line Efficiency Tracking Software)
Take advantage of
SmartPAC 2’s built-in Ethernet connectivity to communicate over your network.
Send and receive text messages, display setup sheets stored on a central server, back up your tools to a remote location, and view pressroom status over the network and internet. When you connect your equipment to LETS, you can collect production data, feed critical parameters reports automatically, view machine status in real time, and schedule a prioritized job queue for each machine.
To learn more about Wintriss Controls, please call 1-800-586-8324 or visit www.wintriss.com. ®2010 Wintriss Controls. All rights reserved.
22 MetalForming/February 2011
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