Introducing 5-axis machining onto your CNC machine shop floor isn’t a guaranteed way to increase productivity, increase efficiency and increase profits. To get these benefits, you must make the most out of your CNC machine tools and, essentially, become a ‘top performer’ in 5-axis machining. These top performers, or ‘top shops,’ machine more parts, have less machine downtime and have more sales per employee and machine tool.
But how do you become a top performer at 5-axis machining? In this article, we explore the actions manufacturers can take to elevate their 5-axis machining to the next level.
Check your machines capability
A common misconception in CNC machining is that the accuracy of a 5-axis machine is guaranteed. But after continual use, it is only natural for accuracy to deteriorate over time. Furthermore, if the machine has been setup inaccurately or a crash has happened at some point, accuracy will also be negatively affected.
Top machine shops assess their machine’s capability before machining anything to ensure their CNC 5-axis machine tool will machine parts to tolerance. Tools like MSP’s NC-Checker automatically test the geometric and kinematic performance of the machine, to highlight any errors and determine if parts will be machined within tolerance or not. Any errors can be fixed before machining starts to save parts from unnecessary damage and failing final inspection.
Automate
Top performers in 5-axis machining will have at least one element of automation within their processes. Automation eliminates a lot of errors and opens many doors when it comes to the 5-axis machining of parts.
5-axis machines are designed to machine complex components, however, if any manual processes are used in their setup or part machining procedures, these components may be machined inaccurately and fail final inspection.
Top shops will automate any manual process (such as probe setup or part alignment) to remove human error from the equation and ensure their machines are only producing right-first-time parts, every time.
Another common feature of automation, that top shops take advantage of, is the ability to run machines lights-out 24/7 and maximise the capacity of each of their machine tools; maximising their ROI. In fact, top shops tend to run their machines 25% longer than other machine shops. This all leads to greater productivity and greater profitability.
Diversify
Being able to machine different types of parts, from the simplest to the most complex components, is a common feature of top shops. They are less likely to struggle when demand for a certain type of part is low or will take on a more strategic approach and choose to focus on more profitable parts if needed at certain times of year.
To do this, automation is again the key. It allows processes to become more generic and suitable for a range of parts. For example, tools like MSP’s NC-PartLocator, automate the process for aligning a part on the machine. This product removes the need for bespoke fixturing and means any part can be placed on the machine and found to within microns of accuracy within minutes (regardless of the complexity).
Invest
Top shops also make significant investments in their workforce and understand it is as important as the investments they’ve made in their equipment and processes. They ensure the team is trained on how to get the most out of any investments in equipment, metrology software or automation tools. Only then can the true potential of this investment be fully realised. If staff are trained, not only will they be using the resources correctly, they can explore how to push the boundaries of what is possible with these resources.
Furthermore, the introduction of automation into 5-axis machining processes, frees up operators from simple manual tasks and allows them to move into more strategic areas of the business and even provide input on the business’s long-term goals, helping to take these shops to the top.
Summary
The article has provided key areas to focus on if you are interested in becoming a ‘top shop’. But this is all irrelevant without the right mindset. Top shops rise to the top because they are always looking ahead to the future, looking for areas for improvement and focusing on providing a better service for their customers. By starting with this mindset, the rest will come naturally and a top performing shop floor will be within reach.
At MSP we have helped many manufacturers become top performers in 5-axis CNC machining. Get in touch with us today and we can advise on how you can become a top peformer too.