Tag : machine shop

manufacturing automation

Robots on the Rise — Rapid Advances in Automation

It is common knowledge that companies and educational institutions are doing what it takes to keep up with the ever-evolving field of automation.   Robots and robotics impacts work and workplaces in new ways, every day.

Automation Changes Every Thing

Automation is changing how we live, how we work, and how we spend our free time. It improves quality of life and productivity. The supply and demand in most areas of commerce and business field are made easier because of various uses of automation. According to economists,  the improvement of productivity that automation provides is positive for improving Gross Domestic Product (GDP), the value of goods and services produced in any given country.

Robots are a newish concept. However, since the beginning of making and providing goods and services, automation has existed. Consider the printing press, the steam engine, or a plow and compare them to a modern-time machine shop.  Machine-tending robots utilize times when production would not occur. They also provide faster and more efficient work. However, while robots are on the rise, man and machine collaborate and work safely in the same space. ” Cobots” use sensors to allow humans and machines to work side-by-side in a machine shop or factory without incident.

Fear Not Robots

A custom machine shop is not the end of employing humans. No historical evidence exists that shows a significant technology impacting human employment levels. The fear that robots will take over stems from Western economies that include robots and automation. The trepidation and hesitation to utilize the latest technologies are unfounded. No one knows where the future of robots and automation will take the human race, but by all accounts, they are positive for all aspects of life.

Aspects of Automation

Companies like cnc automation continually examine the market of robots, machine shop technology, custom machined parts and all things’ automation.  Every aspect requires constant consideration and the evolution of beliefs.

  • The human workforce will remain competitive. Not all companies utilize automation and certainly not assign their labor to solely robots. Factors such as business size, geography, and payoff of the investment of automation technology. Companies that keep a mixed workforce are more productive than those that utilize only one or the other.
  • The rise of robots sees safer work conditions. Workplace accidents come at a high cost, financially and personally. With the latest technology, the most dangerous of tasks are doable by robots. Strains from heavy lifting, exhaustion, and unsafe working conditions are no longer the norm.
  • Automation drives job creation.  Evidence shows that waves of technology have no effect on employment numbers. The opposite is actually true. As technology evolves, the number of required skills in a workplace grows. 
  • Three major industries predict a mostly mixed workplace. Healthcare, manufacturing, and logistics already are putting automation to work with their human labor force. The trend is expected to grow far larger and far faster in the future. Productivity, accuracy, and competition are the driving force in robots and humans working together.
  • Workers report positive job satisfaction and a rewarding salary when automation is part of a company’s profile. Factors such as decentralized management structure,  collaboration with multidisciplinary teams, the wide variety of tasks, and employee autonomy lead to positive workplace culture.

Robots & Manufacturing

Consumers now enjoy a wide-ranging variety of products. The increase in low volume, high mix manufacturing is obvious. Robots and automation is crucial when improving productivity in a non-challenging way. For example, Denver Manufacturing is a highly adaptable region where machine shops work to reduce manufacturing defects, lessen machine downtime, and decrease cost and loss of productivity.

One of the rising trends in automation and robotics is Cloud robotics. It is when data is collected and analyzed for productive and predictive purpose. Robots are becoming easier to afford, more adaptive to constant updates, and straightforward when reprogramming.  Historically, larger businesses were the beneficiaries of robots. However, at a lower cost and easier to operate, everyone is seeing the rise in robots, in a factor or even in a personal home.

Factors that make automation and robotics available to all:

  • Expansion in Company Visions
  • Falling Prices in Components and Custom Machined Parts
  • Mobility and Gripping Technology
  • Cobot Evolution
  • Sensory Technology

Robots — The New Coworker

Workers see an increase in responsibility of workflow and processes in factories and warehouses because of effective integration of robots.  Other workers experience robots as direct coworkers and teammates. For example, robots and workers come together to assemble products or parts and pack them for delivery.

A collaborative robot is one that senses the environment and knows to move or react in tandem with a human counterpart. They work with human labor to lift a heavy object from one place to another for processing, get and carry parts that the worker requires, and perform precision manufacturing in a factory setting driven by human workers.

Actions possible with a collaborative robot includes:

  • Weld
  • Glue
  • Mark
  • Label
  • Solder
  • Lift and Place

The International Standards Organization  (ISO) identifies four kinds of human and robot collaboration:

  1. Safety-rated monitored stop. “This is similar to the approach used with traditional industrial robots,” said Vladimir Murashov, a senior scientist in the Office of the Director at NIOSH and a member of the NIOSH Center for Occupational Robotics Research. “The work stops when a worker would like to enter the workspace of the robot.”
  2. Hand guiding is when a robot moves with the help of an operator.
  3. Speed and separation monitoring are when a robot slows or stops when human coworkers approach or touches it.
  4. Power and force limiting. “This is the approach that has really taken off in the marketplace, so it defines what everyone considers a ‘collaborative’ robot,” said Carole Franklin, director of standards development at the Robotic Industries Association. “Typically, these robots are limited in the payload they can carry and in the amount of force they could exert if they were to strike a person by accident. Also, the power/force-limited robots tend to be designed with rounded edges and softer surfaces that reduce the risk of injury if contact were to occur.”

New technology is often met with skepticism and anxiety. However, no evidence exists that robots take away human employment. Instead, it creates new jobs and optimal productivity. Interested in seeing Sawyer, a collaborative robot in a machine shop? Contact Tag Team Manufacturing in Parker, Colorado.

custom machined parts

The Evolution of Manufacturing

It’s no secret that technological advances have changed every sector of the economy and this is just as true in the world of manufacturing as it is in any other industry. Those who have experience working in the manufacturing field know how the field has changed over the past few decades. Manufacturing has come a long way from the first assembly line and, now, people might think that custom machined parts, advanced machinery and robots are changing the field permanently. In order for a business to rise to meet these changes, they also need to understand the course of manufacturing evolution over the past few decades. How has manufacturing evolved from its roots to the present?

The Early Days of the Manufacturing Industry

Custom machined parts haven’t always been around as manufacturing has changed significantly over the past several decades. Many people look at the advent of the Industrial Revolution as the starting place of manufacturing. This was the first time that interlocking parts were used to create high-output facilities that could produce identical parts quickly. Despite the use of machines to produce parts, the human hand still played a critical role.

Unfortunately, one of the major problems with manufacturing during this era was safety. People were intimately connected to large machines with dangerous moving parts. One mistake could place someone in the hospital, rendering them unable to work or provide for their family. Furthermore, there were health concerns associated with many of these facilities. Because many of these factories were coal-powered and workers were kept in close quarters, illness was common. If someone got sick, that illness could spread through the entire building in a short period of time.

Finally, a huge safety issue was fires. There are numerous stories of the early days of manufacturing of large conflagrations that rapidly engulfed entire buildings. One example is the Triangle Shirtwaist factory fire that took place in New York City in the early 1900s. It is still regarded as the deadliest manufacturing disaster in the history of the United States, as it resulted in the deaths of nearly 150 people. Fortunately, technology improved and changes were made that placed worker safety at the top of the priority list.

The Assembly Line Changes Manufacturing

As technology progressed, thinking changed. The leaders of the world of manufacturing looked for ways to increase output to meet the rising demands of consumers. With this, the assembly line was developed. Many people credit the first use of the assembly line to Henry Ford, which he used to build the first affordable automobile, the Model T. In the assembly line, workers are trained to perform the same task over and over again. Because they are performing the same task, they become experts at this task, allowing them to perform this task faster than anybody else. By combining many people who are experts at their singular task, production and output increase. The assembly line completely changed how manufacturing was performed.

Computers Change the Manufacturing Industry

As the 20th century rolled on, computers started to play a role in the manufacturing industry and changed the fundamentals. With the advent of computers, workers became able to give the computer commands, allowing more precise tasks to be performed. The early days of computer manufacturing involved punch cards that were used to deliver commands. Then, the computer would spit out answers or perform tasks based on those punch cards. Computers and machines are able to perform tasks more quickly and more accurately than human hands. By removing humans from the front lines, factories became safer and humans were largely able to work behind operational controls.

Automation as the Next Step

Technology continued to progress and no area was left untouched. This includes manufacturing and its custom machined parts. As computers became both smarter and smaller, automation developed. Automation is the ability of machines to perform the same task over and over again without requiring additional input from the human hand. Automation became common in the average precision machine shop, leading to significantly increased production capabilities. Machines that are automated do not get tired and, thus, led to the development of 24-hour per day production. Furthermore, these automation robots are also more accurate than the human hand. The manufacturing industry exploded as production and accuracy both increased. Instead of humans turning the screws and tightening the bolts, robots were able to do this. Now, the people became responsible for delivering commands to the machines, changing their jobs when necessary.

Manufacturing in the Contemporary World

Over the past few years, there have been several additional major changes in the world of manufacturing. Some of the examples include:

Workers are More Highly Skilled: Because the manufacturing industry is producing more complex items than ever before, the workers must also be more highly skilled. Those who work in the manufacturing industry often have advanced training in areas such as computer science and robotics.

Higher-Value Goods are Produced: Due to the advent of technology, the manufacturing industry is also producing more high-value goods than ever before. This includes advanced vehicles, accessories for computers, and other connected devices.

The Job of the Human Hand Has Changed: The days of workers getting their hands dirty in a steel mill or coal mine are now relegated to the pages of history. Today’s manufacturing employees are working on a squeaky clean factory floor delivering commands to precision computers that perform a majority of the step-by-step tasks. This is both faster and safer than the early days of manufacturing.

Manufacturing in the Global World: Finally, the world of manufacturing is now a global place. Many of the goods produced in factories today are exported to other countries. The original equipment manufacturer (OEM) is distributing products around the world. The growth of logistics has allowed this to happen. The world is more connected than ever before and Denver Manufacturing is at the heart of these custom machined parts.

Without a doubt, manufacturing is going to continue to evolve as technology continues to progress. CNC manufacturing and custom machined parts have already changed the way manufacturing functions. With computers able to perform multiple complicated tasks at the same time, consumer expectations have changed. It is important for manufacturers to stay ahead of the curve and meet these expectations.

Relying on High-Quality CNC Manufacturing

Precision manufacturing, such as CNC Machining, has completely changed the way that products are produced. It is important for manufacturers to rise to meet these changes so that they can remain competitive in the modern world. Having a high-quality CNC Machinist in a custom machine shop in Denver can help a company maintain an edge on their competitors. CNC machinery can help a business quickly produce high-quality results that will inspire loyalty among customers. To learn more about custom CNC precision machining in the Denver area, contact Tag Team Manufacturing today.

cnc machining

What is CNC Machining?

It’s no secret that the work done within a machine shop has changed significantly over the past few years. The world of manufacturing used to be dominated by assembly lines where workers would perform the same tasks over and over again to rapidly produce high-quality products. As the technology in the manufacturing industry has progressed, so too has the world of manufacturing. Now, a large amount of manufacturing is performed by something called CNC machining. CNC machining and CNC manufacturing represent the next generation of manufacturing. It is important for everyone to familiarize themselves with this industry. Those who are best able to adapt to these changes in the world of manufacturing will be best positioned to remain competitive in the next generation.

An Overview of CNC Machining

For those who might not know, CNC machining is the name given to a manufacturing process that is dominated by advanced computer programming. In this process, a high-precision computer program controls the movements of the various tools and machines within a factory. In this fashion, computers are able to control the complex movements of various machines with extreme precision. Examples of machines that can be controlled through CNC machinery include routers, lathes, mills, and more. With the help of CNC programming, 3D cuts can be performed quickly and accurately with only a single set of prompts. In this fashion, efficiency within a factory can increase dramatically and the output of the manufacturing lines is improved.

What Does CNC Stand For?

CNC stands for “computer numerical control” and has changed how an original equipment manufacturer (OEM) functions. Many compare this process to something called limited numerical control. In contrast to CNC, limited numerical control requires human operators to feed prompts into the system. The human hand is responsible for guiding the machines using tools such as buttons, wheels, and levers. In contrast, a CNC system is more like a set of computer components that are running off of software and consoles. Because computers are able to perform tasks more quickly and accurately than the human hand, CNC is superior to other potential forms of control. For this reason, CNC has risen rapidly in popularity when compared to other forms of manual control or limited control.

How Does CNC Machining Work?

While CNC machining is controlled by complicated computer programs, it is important for everyone to understand the basics. When a CNC system is turned on, the required cuts are entered into a software system as programs. These commands are used to control the corresponding machines. Then, their tools will carry out each of these commands are specified in the computer program. In essence, the machine will function as a robot in a custom machine shop.

The CNC programming is controlled by computer code. This is a numerical function that will ensure that the mechanisms are flawless. Even though errors can occur, these programs are far more accurate than a human operator or manual control. Furthermore, a CNC program can even ask a tool to cut in more than one direction at the same time. This expedites the manufacturing process and can increase the output of a factory.

Many of these CNC machines can retain programs in their memory systems with code that is both written and edited by trained computer programmers. This further increases the efficiency of CNC machines. Finally, CNC machines are not static. They can change and evolve as the circumstances require. New prompts are able to be added to pre-existing programs by simple revisions of the code. This means that CNC machines are able to be adapted to carry out different tasks in a machine shop Denver. Their versatility is unrivaled in the world of manufacturing.

What are Some Types of CNC Machines?

CNC machinery is incredibly versatile and can be applied to a wide variety of machines. As technology has advanced, the mechanisms in these machines have been enhanced with digital computers that have made CNC machining and precision manufacturing possible. Many of the machines in today’s manufacturing world are electronic. This means that CNC machining can be applied to almost all of these devices. There are several common applications of CMC machining which include:

Mills: Mills that run via CNC are able to be run on programs that use both number and letter prompts. These prompts are used to guide the machine across various distances, sometimes in multiple directions at the same time. The code that is used to feed a mill can be tailored to meet that needs of the manufacturers. Mills use a 3D system that functions on the X, Y, and Z axis. Newer mills can add even more axes to increase their efficiency.

Lathes: CNC machining can even be applied to lathes. In the past, lathes were dangerous machines that would lead to horrible accidents. Because lathes can now be controlled by CNC machining, the frequency of injuries due to lathes has dropped. Using CNC technology, circular cuts can be controlled and performed with higher precision and velocity. Because of this, CNC lathes can produce more complex designs than those that could be produced manually. CNC lathes typically are controlled by code that supplies commands on two separate axes. More complex lathes can have 3 axes.

Water Jet Cutters: CNC machining has also been applied to water jet cutters. Water jets are tools that fire a stream of water at high velocity. This water is used to mold hard materials, such as metal and granite, with a high-degree of precision. The water can also be mixed with sand or another solute to shape the target accordingly. CNC machining can be used to control both the speed and direction of the water jet. It can also be used to control the width of the stream. As a result, CNC can be used to mold metal and granite into very specific designs with a high-degree of precision.

Plasma Cutters: CNC machining has also been applied to the world of plasma cutters. This machine uses a white-hot plasma torch to cut pieces of metal and other hard surfaces. The speed and heat necessary to cut metal is incredibly dangerous and produced using compressed air and electrical arcs. The ability to control these devices using CNC machining represents an advancement in the world of safety.

A Wide Variety of Applications with CNC. 

Clearly, CNC machining can be applied to a wide variety of different machines and tasks. Because of CNC machining, these devices can be controlled remotely, increasing safety in the workplace. As technology progresses, CNC machining will become even more important to the future of Denver manufacturing. A CNC machinist can use this type of programming to produce high-quality custom machined parts more quickly than ever before.

Safety procedures in a cnc manufacturing facility. Work Safety concept.

How to Stay Safe in a Manufacturing Facility

Safety in the workplace is important no matter what line of work someone is in, but in the cnc manufacturing industry, it’s one of the most important factors. Manufacturing, with its heavy-duty equipment, long hours, and endlessly tight deadlines supporting other industries around the world, can be extremely dangerous if the necessary safety precautions aren’t taken by staff and the managers.

Here’s what manufacturers and CNC manufacturing employees should keep in mind to ensure safety in the workplace.

Ensure Everyone Gets the Same Safety Training

One of the most common causes of injury in the workplace is not adhering to safety procedures designed to keep workers safe. Workers may disregard the rules, forget them after a period of work without being reminded of them, or may never even have been taught them in the first place.

To ensure workers are following safety regulations that will keep them safe, hold regular training courses on how to safely use and handle different machines and hazardous materials in the company and have supervisors watch to ensure workers are following the facility’s protocols.

Wear Safety Gear

Stories of gruesome injuries, disfigurement, and even death from lack of safety equipment have cropped up in countless stories over the years. Sometimes a pair of safety goggles are the only thing standing between a manufacturing facility employee and permanent blindness, and the risk of injury from lack of safety equipment usage is one that can be remediated with minimal expense.

To minimize the risk of injury from improper safety gear usage, all employees should undergo basic safety training, and supervisors should perform routine checks to ensure employees are wearing their safety equipment as instructed. Any safety gear with replacement dates should have their expiration date cataloged so the cnc manufacturing facility can replace them.

Ensure There Are No Slip and Trip Hazards

Slick and otherwise hazardous floor conditions can be extremely dangerous for workers when they’re on the job. A fall can mean sprains, bruises, broken bones, and even muscular tears depending on the severity of the fall. If a worker is holding equipment when they fall, their injuries could be worsened. Because of this, it’s important for manufacturing companies to ensure there are protections in place to minimize the risk of falls in the facility.

To minimize the risk of falls, ensure that flooring in the necessary areas is equipped with non-slip mats. Non-slip sprays can also be applied to reduce the risk of falling, and workers can be outfitted with no-slip boots to further lower the risk. Any one of these would work well on its own, but a combination of the above can greatly reduce the number of falls in the cnc manufacturing facility.

Keep Emergency Exits Free and Clear

Because of the risk of fire and other incidents within a cnc manufacturing facility, it’s important for emergency exits to be free and clear, as well as explicitly labeled to ensure workers know where to go in the event of an emergency. Incidents in unregulated factories in the past have resulted in the deaths of hundreds of workers; these fatalities underscore the importance of having emergency evacuation routes and protocols in place should the worst ever happen.

To ensure clear and easy evacuations in the event of an emergency, clearly label emergency exits and consider marking the paths to them to ensure walkways remain clear at all times. Signs should be posted indicating that a hallway is part of an emergency route, and supervisors should regularly conduct checks to ensure those routes remain clear.

Eliminate Fire Hazards

There are a number of fire hazards present in any cnc manufacturing facility, and some are more subtle than an unspecialized eye could ever detect. Fires, which can destroy expensive equipment and injure or even kill workers, can come from a multitude of different places, so it’s important to prepare as needed to prevent and manage them. To prevent fires in your manufacturing facility, keep in mind these potential sources of fires:

  • Combustible dust.
  • Hot work.
  • Flammable chemicals.
  • Equipment and machinery malfunction.
  • Electrical hazards.

Because of the number of ways a fire can break out, it can be difficult to prevent or reduce the risk of fires in a facility. Follow a regular cleaning schedule to prevent dust buildup, and enforce strict training and adherence to chemical storage and usage policies, as well as safety guidelines for when hot work is necessary. Equipment, machinery, and wiring should be inspected regularly to ensure all parts are in good working condition and all wiring is still workable with no risk of overloading circuits.

Store Hazardous Materials Safely

Hazardous material use and storage can be an overwhelming set of rules to learn. Hundreds or even thousands of chemicals may be used by a manufacturing facility on a regular basis, and though workers may not need to use them all, a single mistake can result in severe chemical burns or toxic gases leaking into the facility.

To ensure safe hazardous material storage and safety, ensure workers are thoroughly trained in the use of materials they will come into contact with, and keep various forms of documentation on hand to assist with storage regulations for every chemical that will see use. Additionally, ensure goggles, chemical aprons, gloves, and eye rinse stations are located wherever necessary to prevent or mitigate accidents.

Report to Your Supervisor if you See Anything

This is perhaps one of the most important safety protocols to keep in mind when you work as a CNC machinist. Sometimes safety standards get overlooked, and the supervisors in the facility may not be aware of them. When you know a safety hazard is present in your area of work, report it to your supervisor immediately before it can become a threat that endangers you or the lives of your coworkers.

Your safety is important. By being mindful of the risks and safety hazards present in a cnc manufacturing company, you can play your part in making your machine shop a happier and safer place for everyone.

CNC Machinist

What you can Expect from a Career in CNC Machining

At some point in his or her life, everyone has to make a decision as to what they want to be when they grow up. It is not uncommon to continue to ask oneself that question into adulthood. If you’ve ever wondered what it would be like to be a CNC machinist, we are here to lay it out for you.

According to the Bureau of Labor Statistics, there are nearly half a million CNC machinists working in the U.S. That number is expected to stay level through at least 2026. If you’re someone who likes to get your hands dirty, to really get in there and find practical solutions to problems that perplex others, a career as a CNC machinist may be precisely what you’re looking for. If you’d rather be working outside or in a custom machine shop setting than sitting behind a desk, read on. There are a number of things about CNC machining that are likely to appeal to you.

This list represents some of what you can expect to experience as a CNC machinist:

You can expect to learn on the job. Although some CNC machinists are trained at vocational schools, community colleges, technical colleges, or through an apprenticeship program, it is still common for companies to create their own training program for the CNC machinists who will be working for them. That’s because most corporations have a very specific manner of doing things, operational procedures that are not taught in other settings. If you’re someone who gets a thrill out of learning new things, the ability to learn on the job may be of benefit to you.

You can expect to be creative. Anyone who has ever worked in manufacturing, whether they were making baseball bats or secret parts for the Pentagon, knows that things can turn a little frantic when anything goes wrong. Every company is beholden to their customers and must follow strict guidelines and delivery dates. If a part is so much as a thousandth of a centimeter off, it can spell peril for the manufacturer. That’s where you come in. CNC machinists are commonly called upon to get to the root of a problem and come up with a creative way to solve it. If you’re a person who has always enjoyed puzzles, or someone who simply likes a good mystery, this job will offer you plenty of opportunities to think creatively.

You can expect to be part of a team. Teamwork is what it’s all about in this job. People count on you and you count on them to make the most of your workday. Whether operations are running smooth as silk or the sky is falling, and upper management is losing their collective minds, CNC machinists work as a team with every other employee in the company. As a CNC machinist, you can expect people to come to you on a regular basis to ask for your opinion and expertise. In turn, you can ask someone else for help when you need it. For some, it’s the camaraderie that makes the job so enjoyable.

You can expect to be know your value. What you do as a CNC machinist is so foundational to your company’s ability to operate that your absence would present a problem. At some point in their live, most people have had a job in which they felt invisible and unimportant. Nothing could be further from the truth for a CNC machinist. Without them, a business would have no way to control quality, and would be far less likely to come up with new innovations.

You can expect to channel your inner Nikola Tesla. As a CNC machinist, you will be part problem solver and part innovator. What commonly happens in the midst of a manufacturing snafu is that innovations are born that can prevent the problem from arising again. You would be the person expected to come up with innovations that work. Everyone has to start somewhere, but the more you innovate, the more confident you become. CNC machining is a job that allows you to try new things until you come across the one that works. And really, that’s how all great inventors got their start.

You can expect to change.  Not everyone is adaptable, not everyone can shift the way they operate. Because of the nature of their jobs, CNC machinists become supremely adaptable, able to veer from the task in front of them to another when it suddenly becomes a priority. If you aren’t especially adaptable going into the job, you can expect to learn the skill out of necessity.  Adaptability is a trait that carries over into every other area of your life and will stay with you into retirement. In an ever-changing world, the ability to adapt is priceless.

You can expect your skills to be sharpened. Just as a prize fighter become stronger through sparring, your work as a CNC machinist will hone your mental skills. Each day, you will learn something new. Each frustration (and there are frustrations) will bring with it a chance to problem solve. Every level of company hierarchy that you interact with will teach you more about how a corporation works. Through this one job, you will grow intellectually and socially. If, at some point, you find yourself moving to a new company, you will find that you can use what you learned through your first experience as a CNC machinist.

You can expect to be on the cutting edge of technology. Computer Numerical Control (CNC) machines are a blend of digital and physical technologies. In this field it is computers that provide instructions to tools of the trade, such as lathes. For example, it is a CNC machine that allows for the precise shaping of raw materials like plastics or metals. Computers are used in every step of CNC machining, and as a CNC machinist you are the person who is counted upon to understand what’s going on with each step and to troubleshoot in order to keep operations running smoothly. Your computer skills and the desire to learn more are essential for success.

You can expect every day to be different. There is no typical workday for a CNC machinist, primarily because it’s impossible to predict when troubleshooting will be needed or when engineering will change plans midstream. There is very little risk of boredom in this job, a benefit for anyone with a curious mind.

Each person on this planet has a different skill set and different goals that drive them. What most have in common is a desire to spend their workdays doing something that has purpose and offers a sense of fulfillment. If you find that CNC machining sounds like something that would fulfill you, why not take a deeper dive and learn more?

Energy efficiency as car speedometer. 3d illustration

Energy Efficiency – The Key to Success in Manufacturing

In today’s world there is a great deal of focus on sustainability and energy efficiency.  It seems everything, from cars to buildings, is measured by its carbon footprint, or environmental impact.  Other countries, such as the United Kingdom, have strict energy regulations in place for manufacturing industries and for machine shops.  The United States currently does not have any formal regulations regarding energy usage, but that should not stop the CNC machinist from doing everything in his or her power to limit energy consumption in their machine shop.

Limiting the amount of energy used within the machine shop has several benefits.  Of course, limited energy expenditure is more environmentally friendly, reducing the amount of electricity pulled from the power grid.  Reducing energy also has a trickle down benefit to the machine shop owner, OEMs, clients, and customers alike.  Less energy usage can reduce the amount of money spent on electricity, replacement parts and tools, and waste material.  Saving money in the manufacturing process is the key to success by allowing the shop to create an environmentally conscious product for less money.

Mindful Process Changes

One way a CNC machine shop is able to become more energy efficient is by making mindful and impactful process changes.  There has been a great deal of research conducted regarding the amount of energy consumed within the manufacturing process.  By making strategic and thoughtful decisions related to the process of creating components, it is possible to create a more energy efficient process.

Cycle Time

Selecting tools that can both increase a faster feed rate, while reducing feed time, is an excellent way to impact the cycle time between completed components.  In one study, simply selecting the right tool for the job made all the difference.  Consider the advantage to using multi-fluted tools.  This is a great way to deliver instant energy savings over the course of the manufacturing process.  The higher amount of flutes allows for a shorter cycle time, creating more parts per minute.

There is some trade off though, so the CNC machinist must be strategic in their selection.  More flutes, and thus more components, is not always better.  In some cases, while more flutes can certainly increase production, wear on the component can become a challenge.  Multi-fluted tools, or specialty tools, can be expensive to replace.  Further, more fluting can often result in irregular wear patterns which means the tool has an overall shorter lifespan.  Understanding the broader reaching purpose for the job, and selecting the right tool, will ultimately find a happy medium.  The key to cycle time energy efficiency is being able to balance the cycle time increases with the life expectancy of the tool.

Coolant Process

Another area machine shops are able to find energy saving changes is within the coolant process.  Often, coolant delivered to the tools via through-tool delivery help to prolong the life of the tool.  This method can increase how long a tool can be used, thus saving money and resources on replacement parts.  Further, using through-tool coolant can make the wear on the various tool components more uniform.  If the wear is uniform, it helps the CNC machinist predict the wear pattern, thus increasing the usability of the tool.

Further, there are methods to use coolant recycling systems.  These systems can easily be connected to the machine plant cell.  They work by combining a combination of recycled coolant with new coolant.  Studies have shown that by mixing recycled and new coolant there are no noticeable differences in performance.  Not only does this recycling method help to reduce coolant costs, but it has also shown to cut water usage by upwards of 10%.

Software Programming

Using various available software programs to better aid in the manufacturing process, particularly for custom machined parts,  helps to save energy.  Specialized programing is available to help create a custom tool path.  This allows the user to maintain uniform stress on the tool, keeping constant and even pressure, to create a curving, circular path.   Using this continuous, smooth motion allows the machinist to create the component with faster cutting speeds, without risk of tool damage with sudden, sharp turns, thus reducing energy costs.

Another software element indispensable in precision manufacturing is specialized programming that allows the tool to cut with uniform force.  Having a steady cutting force results in energy reduction without varying forces and additional electric input to adjust for changing pressures.

Machine Tool Selections

Aside from making logical and strategic processing decisions, the tools within the machine shop itself can be energy efficient.  There are several tools designed for energy efficiency, especially with the eco-friendly mindset of several companies and customers alike.

Limit Base Load

There are many energy-sapping functions within a tool that can go unnoticed, aside from the immediate energy load required to operate the tool during active phases.  Many auxiliary parts continue to run, even while the tool is in between phases.  The tool’s base load still consumes energy even while the tool is resting.  Luckily, there are many new tools that can be switched off during these non-productive phases which can help save on energy costs.

Tool Selection

Addressed earlier while mentioning the practice of selecting the right tool to increase cycle times, tool selection can also impact the amount of energy consumed.  Of the many components, a spindle can greatly impact the tool’s efficiency.  If the spindle drive is run too slowly, below it’s intended operating speed, it can eat up a tremendous amount of unnecessary energy.  Further, throttling the tool to reduce the speed only increases the time it takes to manufacture a component.  Increased manufacture time leads to an increased use of electricity.  It is recommended that spindle motor efficiency is considered for the component in question.  Sometimes energy efficiency can be improved by using synchronous motors as opposed to asynchronous motors.

Regenerative Supply Usage

Lastly, tools are now made in precision manufacturing that have a regenerative energy supply.  Traditionally, fast moving tools require an internal braking system to slow down the acceleration.  In a non-regenerative system the power used to brake the tool is converted to heat, from friction, which is then lost in the overall process.  Regenerative tools are now available that redirect that lost energy into useable kinetic energy, sent right back to the power grid.

This regenerative supply can help save energy in several ways.  Not only can regenerative power help maintain consistent power to the tool, foregoing the momentary power loss sometimes exhibited when the tool starts and stops, but it can also help in processes that require multiple tool changes.  In systems that require one, or multiple tool changes within 100 seconds regenerative power supplies are able to keep constant energy to the system.  In a non-regenerative tool, the power it takes to restart the machine after a tool change spikes, drawing an excess amount of power from the grid.  This can be avoided with a regenerative tooling system.

Just because the United States has not fully regulated energy consumption by machine shops nationwide, does not mean manufacturers are not interested in the valuable savings associated with energy efficiency.  Conserving energy is a key factor for an original equipment manufacturer in the Denver manufacturing market.  Between prolonging the life expectancy of tools, saving money on energy costs, and making environmentally friendly choices it is clear that energy efficiency is the path for a successful manufacturing process.

Check out another article on renewable energy in Manufacturing.

CNC machine at work

Challenges Manufacturers will face and how to overcome them in 2019

Manufacturers are constantly faced with a variety of challenges and staying competitive and profitable requires the ability to identify issues and enact effective resolutions that can adequately provide a remedy. One of the biggest challenges manufacturers will face in 2019 is creating new markets for custom manufacturing. Perhaps a company can identify a need for a particular product for an emerging market, but creating the avenue to successfully engage that need and fulfill the gap poses a definite challenge.

Identifying Emerging Market Potential

The ability to identify an emerging market and firmly secure a place for custom and precision manufacturing companies within that market is one of the keys to promoting growth and remaining competitive in an ever-changing business landscape. Each year, there are new products and services being developed in mass for the consumer marketplace. If a manufacturer can get a lead on identifying the next big market in which they can provide custom or precision manufacturing, they will have an advantage over the other competitors.

The most effective way to identify these new emerging markets is through research. Part of that research may also involve engagement with a variety of potential consumers across several demographics to establish viability. Having highly trained and insightful staff who can accurately gauge the interest in a particular emerging market and focusing in on specific details that involve providing necessary manufacturing processes will allow companies to partner with new and exciting businesses.

Show How Custom Manufacturing Can Replace Traditional Methods

An effective way to secure the confidence of new clients in emerging markets is to show them how manufacturers can improve on a product and make it more appealing and of a higher quality. Replacing traditional manufacturing that can’t offer the same benefits will allow those products to be more well rounded and versatile. Adding better, high quality 1 features and making more versatile products will benefit all parties. Here are some key points to address and focus in on when presenting an argument for selecting customer or precision manufacturing for new emerging markets.

  •  Value

One of the most important topics related to manufacturing is value. Manufacturers should focus on proving their clients with value they can’t find elsewhere. The argument for value can be presented by highlighting the benefits of using specially created custom parts that add to the function, durability, and quality of a consumer good.

  • Originality

The best way for a product to stand out from the crowd is by having the originality factor. Businesses which feature products that are unique in design and provide specific features that other products in a competing market can’t offer will allow them to create a niche for themselves and provide an extra foothold. Manufacturers can also present their argument for providing originality showing examples of custom machinery that they can provide to produce unique features for a product that make a company and their offerings unique within the market.

  •  Quality

Quality is always a factor when consumers make a purchase regardless of the specific product or market. When working to create a new market for precision and custom manufacturing, highlighting the quality factor they can provide is essential to partnering with new companies within an emerging  market. Pinpoint exactly how the manufacturer can provide a high level of quality that sets their brand apart and makes it an attractive option to consumers.

Utilize Tax Credits For Research Funding

As mentioned previously, one of the keys to creating new markets for custom and precision manufacturers is through research. These companies can actually receive tax credits by using R & D tax incentives. They were enacted in 1981, and were designed to assist companies that are producing new products or even improving on an older variety of product. Harnessing these tax credits will allocate additional funding for research and development to help create and establish new markets for the manufacturing companies. The following are examples of how these tax credits can be utilized for manufacturers to create new markets.

  • Research conducted at institutions such as colleges or other research organizations.
  • Expenses related to employees who play an integral part of the companies research and development.
  • Third parties who are hired to conduct research and research related tasks on behalf of a manufacturer.
  • Tangible supplies that are used to conduct research and development. This tax credit covers property and land improvements related to these processes as well.

In order for a company to qualify for this tax credit, it must fall within the guidelines presented by the IRC section 41, which defines the protocol. Essentially, these guidelines are used to demonstrate how a manufacturer is creating new or improved products. This tax credit can also apply to new software, inventions, or techniques that can be used within the consumer market. In the case of software, there are additional qualifying criteria which must be met to qualify. These tax credits can prove to be especially beneficial for research and development of a CNC Company and American manufacturing companies. These credits can dramatically reduce the cost of staying on top of development of new machinery and equipment necessary for working within new markets.

Companies producing machinery and precision manufacturing equipment must constantly evolve to remain a competitive entity within their market. This entails the use of a combination of research, development, technology, and creative marketing skills. Creating new markets to work within may be one of the toughest challenges these companies face in 2019, but with some insight and a solid strategy to appeal to those key individuals working to establish emerging markets, they can rise to the occasion and provide quality products and machinery these new companies need to provide products consumers want to purchase. For more information, visit the Tag Team Manufacturing website and browse the blog. Tag team is a CNC company and American manufacturing partner dedicated to providing clients with the parts they need for their businesses.

Continuous Improvement Always Get Better Speedometer 3d Illustration

Improving your Machine Shop

A machine shop can be compared to the parts that are manufactured on a daily basis, with many moving parts, all of which needs to work together in synchronized processes to achieve the maximum efficiency in a machine shop. It’s a delicate balance to keep the machines running at tiptop condition and all the employees working efficiently as well.

 

Keeping Your Processes Updated

 

Machine shops of all kinds need to be aware of current trends and standards in their industry to increase your efficiency in the CNC machine shop. The Industrial Internet of Things or IIoT is a relatively new process to help revolutionized the way that we look at different prototype designs. It also monitors the specific customer feedback to newer products and with the rise in mobile connectivity; it leads to more networking possibilities. It also has a high level of connectedness between all of the equipment and machines on the shop floor.

 

Employee Education

 

All employees in a machine shop should be properly educated on the OSHA requirements that need to be followed in order to reduce employee injuries that lead to downtime. The employees should be aware of the workplace hazards for their particular part in the machining industry process and how to operate all machines safely in the manufacturing shop that they use on a daily basis.

 

Quality Control

 

The last step in most manufacturing processes include quality control checks to make certain that all parts in a product are the correct size and items such as pumps operate correctly. If your employees are trained correctly to do their jobs, there will be little errors in the final product. However, if one employee makes a mistake more than once, you can have them re-trained so this doesn’t keep happening. Making another component or part to replace a defective one costs your machine shop extra materials, time and labor and can be very costly. On the other hand, the QC inspector may actually notice that a setting on the CNC machine needs attention by finding inaccuracies in the products made.

Examining the Workflow

 

The process of examining the workflow in your local machine shops can lead you to realize that it is not running as efficiently as it could be. You may be able to improve your daily operations significantly after an inspection by analyzing your shop processes. Lean manufacturing processes are the route that the product travels through a machine shop in the manufacturing stages. For example, if parts are produced in a CNC Machine Shop and the process starts at the front of the shop, then the part moves to the back of the shop for the next phase in the process, then time is being wasted by the two workstations not being next to each other in the shop. It may not seem like a lot of time to walk several hundred feet from one area to another–but it all adds to the inefficiency of the entire workload in your shop. The best idea is to figure the route that is most commonly used for the majority of materials you produce in Local Machine Shops and place the machines accordingly.

 

Collaborate with Full-Time Employees

 

It’s a great idea to talk to your employees with the most tenure that are full-time employees. These people will have the best ideas to help you to decide about any changes that need to be made in your local machine shops. Most employees will just do their job and not create waves, but if you ask them for their opinion, you may find a goldmine of information to draw on and increase proficiency by leaps and bounds. This strategy also strengthens your bond with employees and encourages input from teammates in the future that will help the machine shop.

 

Keep Realistic Deadlines

 

When bidding on a job, make the deadlines for the products realistic. Employees don’t want to work so many hours that they have no family time to themselves and even if they are paid well for the overtime, they will eventually tire out from extra long hours on a daily basis, which leads to more workplace accidents. Planning the deadlines correctly will give you a bit of leeway in the deadline to account for machine downtime and employee sickness if they should arise.

 

Upgrade Machining Tools

 

For Quality Manufacturing you can upgrade your machining tools to take advantage of the newer processes of additive manufacturing and 3D printing to reduce the costs and time of having to do custom tooling by hand. These types of tools will cost you in the beginning, but your largest budget is usually the tooling needs and in the future when the tools are paid off, it will pay for itself in the lower amounts that you pay employees for labor and the time saved.

 

Routine Maintenance

 

Routine maintenance, preventative maintenance or PM, helps keep all of your equipment in functioning order in your Manufacturing Shop. It’s best to have all machines examined at the beginning of the workday to see if they are operating correctly and have employees fill out check lists. It’s much less expensive to have specific intervals for routine maintenance than to have a major setback when a machine goes down. Downtime is not only expensive because you need parts and labor right away, but the parts may not be available for a few days, which will delay you reaching your deadlines and it could cost you future jobs from a customer.

 

Machine Downtime is Your Enemy

 

Machine downtime is the leading cause of inefficiency in any machine shop. You can make some decisions if you keep good records on all the machines and tooling devices in your shop. Make a record of machine downtime on each machine and find the cause of it. Keep records on how many machines are down and for how long. If one goes down often and it has the scheduled maintenance that it requires to be up and running, you may think about a replacement instead. You can assign team members from a different area to do the inspections as they may notice something that isn’t right on a machine that took a long time to surface, whereas the member that uses the machine daily may not notice because the inefficiency occurred over quite a bit of time. Also, make note of the corrections that were made and if they were efficient or need to be changed.

 

Following these ideas can help your machine shop to operate efficiently by timely operations and lower labor costs, extend the life of your machining tools and help to keep great team members on board with you.

5S. Kaizen management methodology. Workplace organization method that uses a list of five words.

Enhancing Workplace Safety with 5S

5S is lean Six Sigma approach designed to reduce waste and maximize productivity by keeping an orderly workplace and achieving consistent results that can be checked via visual cues. Implementation organizes the workplace within its existing framework, and this is the first step toward a lean Six Sigma effort. However, in an advanced manufacturing environment, there are many benefits to adopting these practices outside the formal Six Sigma system.

Benefits of 5S in an Advanced Manufacturing Environment

Developing consistency and organization leads to a conscientious attitude and a safer, more efficient workplace. Conversely, when defects and waste aren’t measured and controlled, costs begin to pile up. Here are some examples:

  • Output falls short due to variations between crews.
  • Utilization is reduced due to longer-than-expected product changeovers.
  • Missing parts make it necessary to rush in a new one

Companies try to guide improvements via Six Sigma, Lean, or Total Productive Maintenance programs. However, studies show that up to two-thirds of such efforts fall below the expectations of stakeholders. Learning these methods is easy, but putting into action is not due to the following:

  • Process improvements decline.
  • Continuous improvement isn’t realized or prioritized.
  • The initiative isn’t global enough.

5S is One Solution

Companies like Danaher and Toyota went through the 5S program to develop positive cultures. 5S engages people to contribute to a visually-oriented organization, where cleanliness facilitates increased safety, productivity, and quality.

5S forms the foundation for more disciplined actions. Workers who put their tools back in place are more likely to follow production standards. Its visual nature makes it easy to spot items that are out of place. It lays the way for continuous improvement and provides:

  • Cleaner, safer work areas with fewer tripping hazards
  • Less wasted time searching for tools and materials that are more accessible
  • Unneeded items are eliminated so that less floor space is required
  • Improved self-discipline fostered by the visual nature of 5S, which makes abnormal conditions stand out
  • Improved culture due to 5S-motivated teamwork and motivation

What are the 5S’s?

The components of 5S are sorting, simplifying, systemic cleaning, standardizing and sustaining.

  • Sorting activities eliminate unnecessary items from work areas in order to clean it.
  • Simplifying arranges the work area for safety and efficiency.
  • Systematic daily inspection of facility and equipment helps determine if corrective action is needed.
  • Standardizing makes abnormal conditions stand out so that the workplace organization is sustainable.
  • Sustaining aims to keep current improvements to allow further progress to be made.

Implementing 5S

5S is not a housekeeping activity. Instead, 5S has to be a team effort and everyone should be able to tell instantly what’s out of place. With organization forming the crux of 5S, it’s vital to start with getting rid of unneeded items.

Sorting

During this phase, employees can sort and clear their work areas. This can take weeks in each department as everyone works to establish criteria for what to throw out. Much like cleaning your closet, anything not used for a year can be removed or put in a holding area. Disposing of uneeded items may mean transferring them elsewhere in the company, selling or discarding them. Then, the employee can conduct an initial cleaning.

Simplifying

Simplying gives everything a home and places each item in order of efficiency. Frequently-used items, for example, have to be close to where they’re used as possible. To accomplish this task:

  • Pick a spot for each item arranged in order of frequency of use and take safety precautions into account.
  • Label items so that there’s a home for everything.
  • Create a process to replenish supplies.
  • Document the equipment, layout and plan to replace supplies.

Systematic Cleaning

Systematic cleaning creates a document that enables inspection of the area. Everything should be swept, mopped and dusted and kept neat and clean with rags or brooms. Daily cleaning and inspections should be easy. Inspections include:

  • Identify points to check.
  • Define acceptable condition.
  • Mark equipment that has visual indicators such as gauges.
  • Conduct cleaning and visual check parameters.

Standardizing

Standardizing ensures that all workers understand the expectations.It is the workplace team that establishes the set of standards they will follow. It’s crucial that everyone has some involvement. Here are the steps to standardize the 5S processes.

  • Establish a checklist for the work area. The checklist should show everything the team checks during self-audits.
  • A multi-level audit system helps to make sure that the organization fulfills the overarching 5S goal of sustaining the work areas so that the system can evolve to more stringent controls and process improvements.
  • Establish and document a single source of truth as to the 5S processes for the company
  • Add new standards to the master document.

Sustaining

Sustaining is considered the hardest “S.” However, it shouldn’t be if you let the 5S system work for your advanced manufacturing company. At this point, you should have engaged everyone in the work area during 5S activities and have a “tell at a glance” visual workplace. If this is so, then sustaining is much easier. That is important, but not sufficient. A more systematic way to prevent backsliding and to foster continuous improvement is needed. The steps of sustaining are:

  • Define the 5S overall grade.
  • Perform routine 5S checks via the 5S checklist.
  • Address new opportunities that are uncovered during routine checks.
  • Conduct scheduled, routine checks by supervisors or someone not directly from the work area in the machine shop that is being inspected.

Perform higher-level audits to evaluate how well the 5S system is working overall. For example, are there systemic issues with sustaining 5S? Often, the company’s safety committee is an excellent body for conducting these audits.

When you develop sustaining activities everything that follows becomes part of the 5S process and future refinements. When items are returned to their place, the entire operation is smoother. When something is out of place its cause is probably that the organization needs to be tweaked so that it’s convenient. The work team should be the ones who safeguard the sustainability of 5S and improve morale, safety, and productivity.

CNC machines at the plant for the production of valves. Factory workspace

10 Amazing Benefits of One-Stop Machine Shop Employment

Have you ever thought about pursuing a career in manufacturing? Whether you realize it or not, there are lots of hidden benefits for working in a CNC Shop. Like buried treasure in a forgotten hill, machinists and manufacturers have lots of career perks that most people overlook. Let’s review the Top Ten benefits of working at a machine shop that can do just about anything!

1. An Easy Educational Foundation

Many jobs in the medical, educational, and legal industries require at the minimum a bachelor’s degree, but you only need a degree from a technical college as a foundation for a great machining career. From there, you can enroll in a state sponsored apprenticeship at a machine shop. This combined time is about the same as getting a master’s degree, but it’s a lot more affordable and you’ll already be working by the time you become a journeyman and the apprenticeship ends.

2. Creative Problem Solving

Machines are anything but boring! Smart career machinists look at manufacturing problems that pop up as career opportunities. If you love to tinker with parts and find new creative ways to engineer things and solve intricate problems, a machine shop career is the perfect fit. You just might solve a production issue that other machinists won’t have to encounter again in the history of manufacturing!

3. Lasting Relationships

One of the most important things about a manufacturing career is building lasting relationships with your customers and those who work in your environment. With this in mind, you’ll enjoy new opportunities that open for you if you carefully cultivate these relationships.

4. Opportunities with Innovation

What an exciting time to be in the manufacturing industry! Each year, new technologies are implemented in manufacturing plants that produce more products faster and make workers safer. From tool and die to robotics, young career mechanics and machinists have awesome things to look forward to at a precision machine shop as products in many industries are becoming more automated for the Internet of Things, a not-so-distant future where many common household items like cars, appliances, and even clothing will be connected to the internet. And as a machinist, you know what that means – more things to fix!

At Tag Team, automation is coming alive through the CMM and Smartscope.

Meanwhile, Tag Team Manufacturing has innovation right inside the CNC Shop. The Smartscope and the Coordinate Measuring Machine offers remarkable precision and ensures quality for checking thousands of parts in a single day. This helps ensure that the high demands of delivery schedules are met for each client we work with. These innovations and more are what make the manufacturing industry all the more exciting!

5. A Steady Income

Dedicated machinists who have completed their apprenticeships and become nationally certified enjoy good and dependable wages. Depending on where they work, they may also have good health insurance and vacation time benefits too. These factors help secure a steady income and a good retirement down the road. For more information about Tag Team Manufacturing’s competitive benefits package, contact our CNC Shop for more information.

6. Consistent Work

Thanks to an increasing interest in American made products, demand for skilled manufacturing has gone up, and that’s not diminishing anytime soon. In fact, manufacturing companies are seeking to fill more job openings now than ever before. In some cases there are more spots to fill up than they can keep up with! That’s good news for the career machinist. Work certainly won’t run out for a very long time.

7. An Active Lifestyle

Can’t stand the thought of being chained to a desk job? Do you like to get your ‘hands dirty?’ Manufacturing just might be your thing. Work life on the plant floor and job sites connected to manufacturing is as different from an office like night is to day. It can be very physical and hands-on. You’re very much a part of the action, so to speak. There’s a lot of strategy and critical thinking involved. And machine grease. Lots and lots of machine grease.

8. Made in America – by You!

Whether it be a old school metal machine shop or a modern CNC shop, there’s something wonderful that happens inside the first time you make something all on your own with your hands. A spark ignites, and you feel satisfied that you made it. Right here in America. And your customer will use it to suit their purposes. No matter how long you’re in the business, that feeling never gets old. That alone is a great reason to start a manufacturing career!

9. Making a Difference

It’s one thing to do a job well, but it’s completely another matter when it’s a job that makes a difference in society. A one-stop metal machine shop can make parts for many industries, from hospital cardiac devices to aerospace plane parts to decorative ironwork that makes a homeowner feel good about where they live. A machinist’s valuable skills can do a lot of good in American society, in many ways. And that’s what makes this industry a rewarding experience.

10. Work with a ‘Smart Robot!’

Who says you can’t have fun with manufacturing? Meet Sawyer, the Smart Robot at Tag Team Manufacturing. With his state of the art technology, Sawyer directly communicates with the machine at the CNC shop to perform multiple tasks at metal fabrication, procedure testing, box assembly, and more with his robotic arm. With Sawyer’s help, Tag Team Manufacturing has multiplied annual productivity and workers are safer. Plus, it’s just plain fascinating to watch Sawyer work on his own!

As mentioned before, now is a great time to begin a rewarding career in manufacturing! Did you know that Tag Team Manufacturing is hiring? Check out our positions here to see if we’re a good fit together. You can also contact us directly. We’d love to get in touch with you!

If you’re a potential client interested in Tag Team’s manufacturing services, you can find out more of what we do here. Thanks for visiting! We look forward to meeting you soon.