1. Attacking waste in manufacturing
Renishaw plc
19/09/2018
Attacking waste in manufacturing
Eliminating non-value added activities that consume time and resources
Confidential

2. Attacking the enemies of productivity and profit
Public enemy #1
Public enemy #2
Waste
Variation
Non-value added activities consume time and resources
Variation in manufacturing results in repair, rework and loss
Renishaw manufacturing technology reduces waste and variation
9/19/20189/19/2018

3. Reducing waste and variation
We help you to...
automate machine set-ups
automate machining processes
reduce inspection costs
accept parts off your machines
Resulting in...
increased shop throughput
reduced machine downtime
shorter production lead times and dependable production schedules
less scrap and rework
higher productivity
more profit to your bottom line!
9/19/20189/19/2018

4. What’s the best way to measure your performance?
Throughput
number of pieces produced in a pre-determined period of time
Efficiency
machine / human performance related to a pre-determined standard
Utilization
% of time a machine / human is actually used to produce product
Productivity
a product of efficiency, utilization, and throughput
Cycle time
can be: machine time, cell time, or lead time
Lead time
time to fill a customer request from receipt of PO
What do your customers care about?
Lead time & price!
9/19/20189/19/2018

5. Renishaw’s products redefine cycle time
“If I’m cutting chips, I’m making money”
You get paid for parts, not for cutting chips!
Cycle time is not the time required once the Start button is pushed and the operator removes the part!
Cycle time is the total time required to complete one part, or one batch of good parts
includes: set-up time, queue and move time, time awaiting operator attention, inspection time, rework time
Renishaw’s products help you make the greatest amount of good parts in the shortest amount of time!
9/19/20189/19/2018

6. Non-value added activities consume time and resources
Renishaw plc
19/09/2018
Waste
Public enemy #1
Benefits of Renishaw probing
Public enemy #1
Waste
Non-value added activities consume time and resources
Manufacturers who understand Renishaw probing save DAYS not seconds by reducing set-up times and eliminating machine downtime through automated process feedback directly on the machine tool
Confidential

7. Traditional manufacturing environment
Waste
Public enemy #1
Traditional manufacturing environment
Available production time on a typical CNC machine tool
Machining centre cutting time - % of time spent cutting chips
VMCs 50%
HMCs 70%
Five out of 10 verticals are waiting for something!
3 out of 10 horizontals sit idle!
9/19/20189/19/2018

8. Non value-added processes
Waste
Public enemy #1
Non value-added processes
Non value-added processes are any action that doesn’t change product configuration, or which results in parts that do not meet specification
inspection, set-up, adjustments, queue-and-move time, etc…
plus
machining bad parts, rework, tool breakage, etc…
You are only adding value when you are machining a part that meets specification
minimize non value-added processes to maximize your productivity and profits
9/19/20189/19/2018

9. (except time spent making bad parts)
Waste
Public enemy #1
Non value-added processes
Mostly value-added
(except time spent making bad parts) %
Non value-added
9/19/20189/19/2018

10. Typical non-value added activities
Waste
Public enemy #1
Typical non-value added activities
Time consuming activities during CNC machine set-ups:
measure tools and update offsets
mount and indicate part and fixtures
identify and update machine work offsets
first part off inspection to verify set-up
adjust rough and finish tools to specification
adjust work offsets
cut a second part
repeat inspection of altered process parameters
Renishaw’s products eliminate or reduce these non-value added activities!
9/19/20189/19/2018

11. Waste Waste What’s your machine doing while you inspect?
Public enemy #1
What’s your machine doing while you inspect?
While you inspect, your machine is:
either IDLE
or making more parts, which may be SCRAP
Waste
Probing on your machine, to set parts and tools or to control critical features, minimizes downtime and waste
less manual intervention
more GOOD parts per shift
more productivity and profit
9/19/20189/19/2018

12. Is your quality control detection based?
Waste
Public enemy #1
Is your quality control detection based?
Cannot inspect quality into your product
Once a defect is generated, cost and schedule concerns multiply
Detection mentality - creates planned delays throughout your process
Detection costs money $$$
Inspecting good parts, parts that meet all print specifications, is a waste of time, money and manpower!
Detection is
NON VALUE-ADDED
9/19/20189/19/2018

13. $ $ Waste Prevention-based process Controlled WASTE
Public enemy #1
Prevention-based process $ $
Prevention
Detection
Process Design
simplicity
robustness
reliable
repeatable
documented
Controlled
Inspection
Rework
Repair
Scrap
Rejections
Customer returns
Schedule losses
Warranty costs
WASTE
Prevention is VALUE ADDED
it contributes to making GOOD parts
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14. Resources required during
Waste
Public enemy #1
Prevention-based manufacturing
Prevention based
Production starts
Resources required during
product life cycle
Process design
Process control
Detection based
Product life cycle
9/19/20189/19/2018

15. Prevention-based manufacturing
Waste
Public enemy #1
Prevention-based manufacturing 70 80 90 %
Renishaw manufacturing technology delivers prevention-based manufacturing
9/19/20189/19/2018

16. How do Renishaw products eliminate waste?
Public enemy #1
How do Renishaw products eliminate waste?
Renishaw products attack waste by:
Automating non-value added tasks such as tool setting and workpiece set-up
MUCH faster and more repeatable than manual methods
calculation and update of tool and work offsets
elimination of human error
defect prevention
Buying parts off the machine tool by inspecting them in situ
less part handling and delay
shorter manufacturing lead times
less work in process
Establishing machine performance before you make the parts
characterise machine tool accuracy
pick the right machine to suit the job
spotting declines in machine performance before they affect quality
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17. Setting tools saves time and reduces errors
Waste
Public enemy #1
Setting tools saves time and reduces errors
NO trial cuts
set a suite of tools in minutes - no manual ‘cut and measure’
probing is more repeatable than manual measurement
tools set while rotating, eliminating errors caused by runout and insert height variation
NO manual offset updates
probing software updates tool offsets automatically
avoid human error & reduce tool and part damage
NO offline pre-setters
set tools in situ at normal cutting speeds for greater accuracy
9/19/20189/19/2018

18. Setting tools saves time and reduces errors
Waste
Public enemy #1
Setting tools saves time and reduces errors
Tool setting examples
Setting a face mill:
length and diameter
tool runs at cutting speed
first trigger finds approx. size
second trigger measures exact size
Setting a slot drill mill:
length and diameter
tool setter mounted outside operating volume
tool can be set anywhere along the beam
9/19/20189/19/2018

19. Probing reduces part set-up times and fixturing costs
Waste
Public enemy #1
Probing reduces part set-up times and fixturing costs
NO trial cuts
find the location and orientation of your parts in seconds, without manual ‘cut and measure’
machine parts right first time
NO manual offset updates
probing software updates work offsets automatically
avoid human error & reduce tool and part damage
NO complex fixtures
no need for precision fixturing - use the probe to find the part
9/19/20189/19/2018

20. Probing reduces part set-up times and fixturing costs
Waste
Public enemy #1
Probing reduces part set-up times and fixturing costs
Part set-up examples
Is your setting process like this?
just press cycle start and go
RAMTIC system, Renishaw
How is it done?
probe datum features
signal reaches CNC via optical transmission
establish work offsets
automatic update
9/19/20189/19/2018

21. Accept parts off your machines
Waste
Public enemy #1
Accept parts off your machines
NO waiting for inspection
establish machine performance, before you start machining
measure critical features on the machine, before performing finish cuts
correlate measurements between the machine tool and your CMM, your traceable measurement standard
NO operator intervention
measure and document your parts automatically
automatic feedback of process parameters (offset changes) to ensure that the next part is right
9/19/20189/19/2018

22. Parker Military Control Systems
Problem:
setting complex aluminium manifolds
need to reduce setting time to release more capacity
Solution:
MP12 probe used to measure key features on the manifold and automatically update the CNC control fixture offsets
allows the process to hold .002 inch true position and .001 inch depth tolerances
Client Profile: Parker Hannifin
Location USA
PARKER HANNIFIN: A diversified manufacturer of motion and control systems for aerospace , automation and other industrial applications
Benefit:
95% reduction in setting time - saving over 30 hours per batch
elimination of manual errors
9/19/20189/19/2018

23. Parker Military Control Systems
Problem:
setting complex aluminium manifolds
3 to 5 measurement activities per part:
find the centre of a hole on the manifold and update the CNC control fixture offset, to hold .002 inch true position on other holes in the manifold
measure the face of the manifold and update the CNC control fixture offset, to hold +/ inch depths from the face
measure the distance between two manifold features from a gage point - these are impossible for the machine operator to measure
“ When the operator had to manually indicate these holes, it would take an average of 10 minutes per hole and require him to manually calculate the work offset and then enter the numbers into the CNC control”.
9/19/20189/19/2018

24. Parker Military Control Systems
Solution:
spindle probe is used to measure the hole centres, face depth and distance between features
probing now part of the part program
updates work and fixture offsets automatically
“ One probing routine takes less than 30 seconds. This includes automatic mathematical calculations from a gage point, using the captured data, and updating the CNC control with new offsets - completely eliminating human error”
9/19/20189/19/2018

25. Parker Military Control Systems
Benefit:
Traditional method
Indicate four holes / part = 40 minutes
Four parts / tombstone = 160 minutes
Lot size of 48 pieces = 32 hours
Shop labor cost $100 / hour
Cost / hr. x 32 hours = $3,200
Using a Renishaw probe
Probe four holes / part = 2 minutes
Four parts / tombstone = 8 minutes
Lot size of 48 pieces = 1.6 hours
Shop labor cost $100 / hour
Cost / hr. x 1.6 hours = $160
total savings of $3040 for one batch of 48 pieces
PLUS
an additional 30.4 hours of production capacity!
9/19/20189/19/2018

26. Probing and calibration add profit to your bottom-line!
Summary
Renishaw manufacturing technology helps you to:
eliminate WASTE by:
automating non value-added tasks
buying parts off your machines
establishing machine performance before your start to cut metal
reduce VARIATION by:
providing repeatable, automated feedback of process parameters
monitoring tools and controlling part dimensions in cycle
buy parts off your machines by:
quantifying, diagnosing and improving machine performance
linking machine tool probing to traceable measurement standards
Probing and calibration add profit to your bottom-line!
9/19/20189/19/2018

27. apply innovation
9/19/20189/19/2018