other words, we would have spent 216 hours in setup over the four months without the LPP. With the automation, we only set up each part once, no matter how many times the part repeats over the months or years.”
This example doesn’t count the time saved on inspection, Irion said. “We might spend a couple of hours on a fi rst-article inspection, for example. With the LPP, we only have to do that once—the fi rst time we set up the part. Because the setups and tools stay the same in the system, we know nothing has changed,” Irion said. Senga’s NMV5000 DCG universal milling machine is credited with being another major time saver. The machine’s fi ve-axis capabilities have allowed machinists to consolidate processes, so what might have taken three operations and three time-consuming setups and fi rst-article inspections now takes only one.
In addition to the productivity enhancements, eliminating setups with the LPP and NMV5000 DCG has done wonders for precision. Operator error has been reduced and the inevi- table micron-level inaccuracies that result from manual setup changes have been eliminated.
“You can’t have any ‘oops’ factors when you’re performing surgery.”
“Many of the sensor parts we’re making go into surgical equipment. You can’t have any ‘oops’ factors when you’re performing surgery,” said Irion. “So that’s the idea of automat- ing the mill department. Our goal is to automate as much as possible, using what we feel is one of the fi nest machine tools on the market.”
Just-In-Time Works for Small Runs Another benefi t of the LPP is the fl exibility that it has given Senga to take on smaller runs. Historically a production shop, Senga has now successfully ventured into the uncharted terri- tory of smaller lot sizes. “We’re still a production shop, but with the machines and the LPP, it’s feasible for us to take on really stringent, low-volume aerospace work,” said Irion. “We’re used to doing 900 parts—these jobs might be as little as nine.” Smaller runs make more fi nancial sense for Senga now because of the installation of the LPP, but Irion said that it required a change in mentality. “As long as we bid jobs prop- erly we can make money. If we’re going to address some of
Available with an integrated force gauge, our NC vise tells you how much holding force is being applied. Minimal effort on the crank handle results in extremely high built-in hydraulic holding force. Now you’ll know if your part is being held properly.
Click “Explore Hilma Vise Products” at www.clrh.com
• Better clamping quality • Correct clamping force every time • Consistent process control • Reduced tool breakage • Workpiece deformation reduced • Ideal for roughing and finishing • Reduced operator fatigue
Carr Lane Roemheld has a full line of robust machine vises.