浙江省醫(yī)療器械經營企業(yè)現場檢查評課件

1、浙江省醫(yī)療器械經營企業(yè)現場檢查評This program is presented at several SME technical clinics; Broaching Technology clinics, the Process Improvement Clinics and the Basic and the Advanced Gear Design & Manufacturing clinics. Gary Rodak, CMfgEGary.RodakMachiningEPhone: 734-904-4060Tool cost improvements are typical

2、ly 15% to 20%.Similar improvements in quality and uptime.This presentation is best viewed in the Powerpoint Presentation mode.This program is also presented at the Michigan Manufacturing Technology Center in Plymouth, MI several times each year. 浙江省醫(yī)療器械經營企業(yè)現場檢查評Machining Efficiencies, Inc. is dedica

3、ted to improving the manufacturingperformance of machining and grinding operations. We focus on improving our clients profitability by identifying specific corrective action that will reduce the process costs.We transfer our knowledge of process improvement techniques to our clients to ensure long t

4、erm effectiveness.We accomplish this through educational seminars and first hand exposure to best practices. Gary Rodak, President浙江省醫(yī)療器械經營企業(yè)現場檢查評We hold several one hour classroom reviews of basic machining process theory and the relationships between filtration, cutting fluid chemistry, biology, a

5、nd metallurgy.These sessions also cover best practices for machining and grinding processes, coolant control, filter maintenance and metallurgy.We utilize your specific or familiar floor problems for customized training programs and implementation of best practices.Our recommendations are reinforced

6、 with customized presentations and reports suitable for quality system audits.Available follow up reviews ensure long term implementation of best practices and problem resolution.We stay focused and are driven to reduce your cost of manufacturing.“We involve you.”浙江省醫(yī)療器械經營企業(yè)現場檢查評 We introduce your E

7、ngineers and Machinists to practical techniques for quickly improving process performance. We show how the worn tool indicates the process conditions and what may be sub-optimized practices. The Program uses familiar tools and processes that benefit from the attention. Simple, easy-to-create reports

8、 are used for follow up and for quality system audits. The exposure to this problem solving technique will be used by the students for the rest of their professional career.Skill Enhancement Program for Engineers & Machinists浙江省醫(yī)療器械經營企業(yè)現場檢查評9 elements of making a good part & why all are impo

9、rtantTypes of metalworking fluids and control parametersChemistry how additives work and what you need to knowBoundary and hydrodynamic lubrication modesOrthogonal geometry in machiningPlane of deformation during cutting controlling it for efficiencyMicrofinish how it is created and controlled at th

10、e cutting edgeFiltration how much do you really need?Biological activity the impact on the machining processCoolant system problem identification and resolutionTool wear patterns and how to read them to improve the processTool wear patterns cause and cure with broaches, inserts, hobs, shapers, reame

11、rs, drills, etc.Tool life improvement and practical techniques (customized program)Tool condition and sharpening techniques (customized program)The costs of manufacturing at a specific point in the total processTopics addressed in the training program and how they relate to each other浙江省醫(yī)療器械經營企業(yè)現場檢查

12、評Following are some slides taken from the presentations.q Identify top 15 to 20 high cost tools or high volume toolsq General audience classroom trainingq Identify tool and coolant system issuesq Investigate issues and root causesq Present findings, reports and recommendationsq Incorporate improveme

13、nts into standard operating proceduresq Follow up key issues and findings *A plant wide program has the greatest impact on costs and involves the greatest number of individuals who can affect the processes.Sequence of events for a plant wide* process improvement program.Overview浙江省醫(yī)療器械經營企業(yè)現場檢查評Techn

14、ical ProgramA Practical Approach to Improving your Machining OperationsCoolant Action in the Cutting ZoneTool Wear Patterns How to Adjust the Process for ImprovementTroubleshooting Coolants in Central Systems浙江省醫(yī)療器械經營企業(yè)現場檢查評Machine a better chip.It is the core of your business1. Reduce the cost of m

15、anufacturing A. With greater tool life. (Lower tooling costs)B. With less tool change set ups. (Less downtime)2. Improve the surface finish during the machining processes.A. More accurate form generation. B. Attain tighter tolerances. C. Better subsequent processes. (Better coating, assembly, etc.)D

16、. Less residual compressive stresses in parts.浙江省醫(yī)療器械經營企業(yè)現場檢查評 Tools Metallurgy Coolants FiltrationMachineThe Costs of Manufacturing“All FIVE disciplines are related and mutually influential”$浙江省醫(yī)療器械經營企業(yè)現場檢查評Identify ALL the Problem(s) with your central system(“Poor tool life or wheel life are used

17、as examples here.”)A. OdorB. Rust and StainC. Loss of filter efficiencyD. Poor emulsificationE. Residual filmsF. DermatitisG. FoamingH. Poor tool life or wheel lifeI. Poor microfinishJ. Poor part size controlK. Paint removalL. Smoke or excessive mistingM. Clinkering of chips or swarfN. FungusO. Seal

18、s or V Belts P. Chip nests (stringy chips)浙江省醫(yī)療器械經營企業(yè)現場檢查評H. Poor tool life/wheel life(These 20 influential components are investigated.)1. Concentration control 2. Microorganisms/fungus 3. Biocide levels 4. Wrong product choice 5. Improper speeds and feeds 6. Wrong tool material choice or wheel mat

19、erial choice 7. Improper resharpening or redressing 8. Misdirected coolant flow 9. Pump sucking air 10. Restricted coolant flow 11. Foam 12. Contamination by hydraulic fluids, way oils 13. Contamination by floor cleaners or machine cleaners 14. Incorrect tool design/wheel application 15. Incorrect m

20、etallurgy of parts 16. Part fixturing 17. Part gauging 18. Prior part processing 19. Filter malfunction 20. Machine/spindle vibration 浙江省醫(yī)療器械經營企業(yè)現場檢查評All of the failure modes are documented with microphotographs for future reference. There are four more failure modes associated with broaching, hobbi

21、ng and other similar processes. They are not included in consideration of the document .Built Up Edge phenomenonChipping WearFlakingSpallingFractureFlank / Nose / Face WearNotching WearThermal Cracking (Shock) (Fatigue)Crater Wear (Diffusion Wear)Deformation WearCobalt LeachingFailure Modes of inserts浙江省醫(yī)療器械經營企業(yè)現場檢查評Identification Ragged edge on insert Poor (streaked) surface finish on parts Irregular wear Leads to catastrophic tool failure (masked cause)Causes Excessive loads on tool Built Up Edge (BUE) Intermittent contact with h