Adrian Hainarosie C.A.D. Mechanical Designer & C.A.M. Programming C.N.C. Manufacturing.

In my entire career #aerospacemanufacturing shop floor production #milling #turning #EDM #gearshapping …etc, I have used many methods in the attempt of increasing the productivity of the entire factory or just sections (manufacturing cell area) and lower manufacturing costs.  In my case some methods failed to achieve the end scope, and some actually exceeded the realistic set target. (I do strive for perfection; realistically you can remove waste from a process at above 90%).

Let’s run a few scenarios and examples for #quality PPAP inspection on #aerospace shop floor #manufacturing environment.  

• Inspecting internal corner radiuses created by the tool’s radius in a milling process- These are features that either cannot be CMM inspected or not #costeffective to be CMM inspected.  The #industry fast pace demand requires a more #productive and #costeffective method – using the classic plasti-mold and shadow graph is an obsolete and #timeconsuming method.

  As more factories are implanting high precision toll pre-setters like #Zoller (for example).   This gives the advantage of measuring the corner radius of the tool in the same measuring cycle, and also setting the tool’s life onto the RFID chip. If these set parameters are not within measured specification, then Zoller’s tool pre-setter will not pass and not write the info onto the #RFID chip.  As long as the tool’s radius will keep its profile within the set tool’s life –and this is to be proven within test trials – we can set a longer inspection increment within production environment.

  One of the best manufacturing software I ever used,  is #Solumina , as per you can  imbed inspection plans in within the manufacturing operations and can set  inspection checks on “first” and “last” component, from a given production batch of let’s say 12 components,  as long at its “flow diagram” function is configured to do so.  @Solumina can be set to record a higher inspection increment, then “first” and “last”, in order to increase productivity

  An advanced CNC milling turning manufacturing production environment is configured for “Lights out machining” utilizing multitask tooling and automated methods for #costefficiency.   So utilizing as much as possible the  same tools across various projects on the same CNC machine will drive out #waste and generate #costsavings.    

 CAM software like @Siemens NX CAM has the ability of feature CAM recognition for #bestpractice #manufacturing methods to  standardize manufacturing methods and tooling – basically each CNC programmer that will create a new NC program will use both tooling and manufacturing methods with proven cutting conditions in order to achieve “ right first time” #manufacturing process.

Vericut to check the cycle time and volume the tool removed to set tool’s life once best practice method is proven.

#SAP to release work orders on the shop floor in a set group and given order to accommodate tool life as per #productionschedule.

 As long as you have all the above tools, and a solid manufacturing method, than there is no #risk of #quality escapes.

• Bottom angle on blind drilled holes and features generated/formed with porting tools.

As long as you use a @Zoller tool pre-setter — this will check the drill’s tip angle.  You do get as standard 140deg.  However various tools suppliers will uses between 136deg.  up to 142deg.  As #DFMEA  .  I do advise for the depth of drilled holes to be given to shoulder as per it’s more accurate to inspect.

There are various chamfers and angled faces that being generated /formed with a porting tool can be passed for manual checks by inspecting the cutting tool on the #Zoller’s tool pre-setter.  Of course use a plug gauge for diameter size and CMM for depths and #GD&T, also various corner radiuses can be passed accordingly measuring the tool’s radius on the #Zoller tool-pre-setter rather than creating a plasti-mold/”wax” on the component’s features and check on shadow graph.

To be continued ….. and revised .

I appreciate your time,   taken on reading my post.

Let me know in the comments bellow ….. Your thoughts … ideas..etc .