Machine shop101 rev_l

Machine Shop 101

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Machine Shop 101

Please silence your phones and radios

Course DescriptionCourse Description

• This presentation takes employees through the fundamentals and best practices of the machine shop

• There is a particular way we do things called “The Haas Way”

• You will learn about how we apply this thinking to what we do in the shop

• Emphasis on what is critical

Course Outline Course Outline

Section 1 – Shop Layout and The Haas WaySection 2 – SafetySection 3 – Work FlowSection 4 – Case Study 20-7016cSection 5 – What is critical? (Quality)Section 6 - Downstream EffectsSection 7 – Competitive EdgeSection 8 – Conclusion Section 9 – Test

Section 1Section 1

Shop Layout and The Haas WayShop Layout and The Haas Way

Last Updated Last Updated 04/12/2304/12/23

Prepared by Jeremy Kermit, MachiPrepared by Jeremy Kermit, Machine shop, Haas Automation, Inc.ne shop, Haas Automation, Inc.

Machine Shop 101 Machine Shop 101

This isn't your daddy’s machine shop!

Tooling 101 PrepareTooling 101 Prepared by Chris Ferrier Manufacturind by Chris Ferrier Manufacturing Engineer Haas Automag Engineer Haas Automation, Inc.tion, Inc.

Machine Shop 101 Machine Shop 101 THIS is your Machine Shop!

Haas Automation has one of the most impressive machine shops in the world!!

2008 Numbers2008 Numbers• At the peak of the economy

Haas posted some impressive production numbers.

• At the highest point we were manufacturing over 1300 machines per month!

• Right now we are setting ourselves up to achieve even better numbers more efficiently.

How do we do itHow do we do it

?? • In order to support customer demands, the

shop must use the most advanced technology, and our Haas culture to produce the parts needed to build our entire product lines

• Technology• Culture

How Do We Do It?How Do We Do It?

• The “Haas Culture” is the underlying force that has brought us to where we are today.

• All Haas employees embrace that culture and work together to keep it strong and evolving positively.

How Do We Do It?How Do We Do It?

• Positive characteristics to our culture:– We are driven to succeed. – We are professional in our

conduct.– We measure our results.– We think globally.– We act locally.

Your RoleYour Role

• You play a key role in the manufacturing process by working in the shop to help produce all those parts.

• You will learn how your work affects your customers downstream (both internal and external)

• Understand that you are part of an exceptional operation!

• Next you will see a video describing the plant’s operations

Video-Haas Factory TourVideo-Haas Factory Tour

Product Lines Product Lines

OVER 50 VERTICAL CNCMACHINE MODELS

TODAYTODAYOVER 20 CNC LATHE MACHINE MODELS

OVER 10 HORIZONTALCNC MODELS

OVER 30 ROTARYINDEXER MODELS

MACHINE SHOP OVERVIEWMACHINE SHOP OVERVIEW

375 CNC (Computer Numeric Control) MACHINES

33 FMS: Flexible Manufacturing

Systems

Robot Loaded Haas MachinesRobot Loaded Haas Machines• Over 20 cells

installed

15 5-SIDE (DOUBLE COLUMN) MACHINES

These machines can cut 5 sides of a part in one setup

OVER 1000 PALLETS IN USE

Section 2Section 2

SafetySafety

SAFE HAZARDOUS

Safety -A Priority at HaasSafety -A Priority at Haas

• There will be other training to cover specifics of detailed safety topics.

• Contact the safety engineer for any specific safety information

Safety information can be found by typing “training” into any web browser and clicking on the “safety” link

SafetySafety

1. Common sense shall prevail!

2. Avoid hazardous situations and minimize risk

Use Your Head!

PPEPPEPersonnel Protective Equipment PPE

What is it?Examples are:

• Safety glasses • Steel toe shoes• Aprons• Gloves• Ear protection• Respirators

Required

Lockout TagsLockout Tags• Tagouts and lockouts

identify equipment or circuits being serviced.

• Tagouts and lockouts are

removed only by the person indicated on the back of the tag.

Lifting Safely-ForkliftLifting Safely-Forklift• You MUST have a license!

• In machine shop, forklifts are used frequently to lift and move parts.

• Make sure to follow the basic forklift rules

Capacity ratings are shown on

placard

Lifting Safely-CraneLifting Safely-CraneLifting Safely-CraneLifting Safely-Crane

Load Capacity

Load Block

Rigging / StrapsInspect. Replace if

needed

Lifting Device

Most accidents occur from “below the hook” and are related to poor rigging

SpillsSpills

• If a spill occurs, do the following:– Contain it – use absorbent socks or red

rags.– Clean it – use degreaser and soapy

water to clean the spill.-Yellow spill kits can be found in every

building with the correct tools to clean up a spill.

• If a spill cannot be cleaned up immediately, set up a barrier and notify security at ext. 8688.

ConclusionConclusion

Always remember:

• Workplace safety starts with YOU!

• Safety is a priority at Haas Automation.

• Be aware of safety for yourself and your co-workers.

• Immediately report any unsafe acts or conditions to a supervisor or manager.

Being safe will prevent injuries

Hazardous situations lead to injury

Section 3Section 3

Work flowWork flow

What do people do with our machines after they buy them?

End ProductEnd Product

End Product

IndustryIndustryThe answer is: To

make parts…for almost anything!

IndustryIndustry

WorkflowWorkflow

Haas delivers machine to customer

Assembly puts parts together into a finished

machine

Machine is shipped from the factory

Parts are stored in inventory, ready to be

assembled

Machine shop turns raw material into machined

parts for assembly

Purchasing buys raw material, cutting tools etc. so the shop can

make parts

Order is invoiced, so Haas can pay for

expenses (like purchase more raw goods)

Customer makes parts for industry

Order PlacedOrder Placed

End result-how do we get here?End result-how do we get here?

Our Goal: On Time Delivery Of A Our Goal: On Time Delivery Of A Perfectly Built ProductPerfectly Built Product

Order PlacedOrder Placed

The Master ScheduleThe Master Schedule

• Master schedule is determined by the company’s forecast

• The schedule projects our goals for the month and year.

• It drives what parts need to be made and what machines will be built

This drives demand in the system to make the

required parts

Workflow-Raw MaterialWorkflow-Raw Material

make parts

Workflow-ShopWorkflow-Shop

parts for assembly

make parts

This is where you fit into helping to deliver a machine

WorkflowWorkflow

parts for assembly

Purchasing gets raw material delivered to the

material yard

WorkflowWorkflow

Material is changed into “machined” parts

(generally in more than one operation)

Raw material is cut away leaving the

finished part

material yard

parts for assembly

WorkflowWorkflow

Parts are inspected before being allowed to

move downstream

material yard

parts for assembly

Inspection of critical features

Parts move onto the next step for a

protective coating, deburring, paint,

hardening, or other finishing treatment

There may be a final finishing operation

before the part is ready to move out of the shop

material yard

parts for assembly

WorkflowWorkflow

material yardWorkflowWorkflow

Parts move onto the next step for a

protective coating, deburring, paint,

hardening, or other finishing treatment

There may be a final finishing operation

before the part is ready to move out of the shop

Parts are moved to inventory and ultimately

to assembly

parts for assembly

Machining Process-First ArticleMachining Process-First Article

• Process repeats• Tolerances are met• Programming is done

correctly• Offsets are correct• Workholding is OK• Tools run good• ETC.

All parts run a “First Article” All parts run a “First Article” before production can begin.before production can begin.

First Article (F/A) checks:First Article (F/A) checks:

Machining ProcessMachining Process

• Photo router• NC code file• Blueprint drawing

To set up the first article To set up the first article part a machinist will get part a machinist will get the current documents:the current documents:

• Tools • Fixture• Material

To set up the first article To set up the first article part a machinist will also part a machinist will also get the proper:get the proper:

What tells you how to What tells you how to get the above? The get the above? The “work instructions”“work instructions”

Mill-fixture Lathe-chuck

Next: material is loaded into Next: material is loaded into the workholding device and the workholding device and clamped in place so it can clamped in place so it can be cut down or “machined”be cut down or “machined”

Machining processMachining process

InspectionInspectionInspection of critical

features

Prior to unclamping!Prior to unclamping!

The part’s position and offset will be lost The part’s position and offset will be lost after unclamping after unclamping

InspectionInspection

Workers will check that all dimensions are within tolerance

When everything is good with the “first article” it is signed off and the production can begin

But how do workers know how to check the parts? ??

Inspection-Inspection-PrecisionPrecision

Low precision

High precision

Medium precision

What tells you how to check tolerances?

5252Answer- the blueprint!

Non critical feature

(rough surface ok)

Non critical feature

(non cleanup ok)

Critical feature

(bore must runout within .0005)Size of hole cannot be below 2.160 or above 2.165

Inspection-Inspection-in processin process

Once first article is done, production can begin to flow with parts being checked “in process” with functional and size gauges

Operators will load and unload, parts will flow to the next area

Now “in process” production can run

WorkflowWorkflow

assembled

parts for assembly

make parts

This is where you fit into the flow

Material movement

Material MovementMaterial Movement

• Ask yourself: “Where is the next place?”• Outside process?• Next machining operation?• Deburr?• Inventory?• Assembly?

– You should use a move sheet – (unless you are moving casting)

• Proper packing reduces cost and damage to critical parts

• It all begins with YOU! • More detailed

information is presented in the Material Movement class!

Move sheet

• Use this Not this

• The reason Haas bought these part specific containers was to prevent damage of critical precision parts

No separators

Material Movement: ContainersMaterial Movement: Containers

• Preventing critical parts from being damaged will benefit the company as a whole by reducing costs and ultimately improving our bottom line

IT ALL STARTS WITH YOU!

WorkflowWorkflow

machine

assembled

parts for assembly

make parts

Material movement

Casting assembly

WorkflowWorkflow

machine

assembled

parts for assembly

make parts

Material movement

Customers around the world eagerly await receiving their machine

WorkflowWorkflow

machine

assembled

parts for assembly

make parts

Material movement

Section 4Section 4

Case Study: A Part’s JourneyCase Study: A Part’s Journey

20-7016C (spindle housing)

A Part’s JourneyA Part’s JourneyCase study: 20-7016C (spindle housing)

Saw cut operation produces blank

A Part's JourneyA Part's JourneyCase study: 20-7016C (spindle housing)

Turn Op1 (first side) Turn Op2 (second side)

Note: Here Op stands for “operation”

Mill Op3 (fixture) Mill Op3 (drill holes)

Finish cut (Op4)

Outside Process

(Black oxide coating)

Assembly

(mount bearings, shaft, cap, etc.)

Break in and vibration analysis

Assembly

(Mount spindle cartridge to machine frame, mount motor)

MotorMotor

Inspect run out, sweep, and squareness of spindle to table

Test cutting functionality

Now the spindle can properly function throughout its service life

Section 5Section 5

What is critical?What is critical?

Something you should ask for Something you should ask for every part you machine! every part you machine!

A turning point; crucial or decisive:

a critical point in the campaign. Indispensable; essential: a critical element of the plan;

a second income that is critical to the family's well-

being.

What is critical?What is critical?

In our case critical means that parts and/or features are

necessary for proper assembly and function of a Haas machine

How to check critical features?How to check critical features?

Check Spindle Sweep In 4 Places

SPINDLE SWEEP TOLERANCE.0005” IN A 10” DIA CIRCLE

Checks like spindle sweep ensure critical parts match up correctly

Critical-Mating FeaturesCritical-Mating Features

• Critical features will be different for every part, but it has to do with how the mating parts assemble together.

• They are the physical, functional, and performance characteristics that uniquely identify a component.

Remember:

FORM, FIT, AND FUNCTION!

What is critical?What is critical? This is the most This is the most important question to important question to ask when making partsask when making parts

How this part How this part assembles assembles dictates what is dictates what is criticalcritical

Non-criticalNon-critical

CriticalCritical

Problem-spindle sweep out of spec!Problem-spindle sweep out of spec!

.0022.0022

.0034.0034

Ideally parts fit together correctly the first time, but when readings are no good we must retrace our steps to find out what went wrong

What happened?What happened?

++Stack up of all the parts in the assembly

Blue highlighted surface are possible causes of problems. See how many other parts need to be checked (because something is wrong)!

Root CauseRoot Cause

If problems are discovered, an investigation and corrective action are necessary.

Find the root cause and fix it!

DisassemblyDisassembly

• Time and money could have been saved by not having to disassemble to find out why the machine will not function properly

Know What is CriticalKnow What is Critical

• Always go to Assembly to see where your parts are used. Ask: “What is critical?”

• Whether running complex or simple parts, the first question to ask is “What is critical?”

• Your help is necessary to prevent unusable parts and wasted time

Critical !!!Critical !!!• In this

example the size of the diameter must be held to +.002 / -.000 and perpendicular to the bottom within .0005 to ensure proper functionality

NOTE: Perpendicular means that the mounting face must be

square (90 degrees) to the bottom

Necessary, but non-criticalNecessary, but non-criticalAlthough this fan is necessary, the bolt hole locations do not need to be to held +/-.0005 for proper functionality

It still needs to be made to the print!

Section 6Section 6

Downstream effectsDownstream effects

A small problem can grow into a big problem downstream

What could affect downstream?What could affect downstream?

• Material

• Fixture

• NC program

• Material transportation

• Tools (holder & cutter)

• Coolant

• Feature size

• Many other variables!

The goal here is to only pass on good parts downstream

TSC pump housingTSC pump housing

Cause: part did not load perfectly in the fixture

Effect: failure at the customer’s shop

Probing issue

Fixture / Loading

Part not loaded in fixture causes uneven dimensions

100100

Field failures

Internal damage

101101

Consequences: Failure Leads To Consequences: Failure Leads To Unhappy Customers!Unhappy Customers!

Customers get angry when their Haas machine does not function properly! And what is worse is our reputation will suffer!

Note: We have internal customers too—who is YOUR customer?

102102

Warranty replacement costWarranty replacement cost

Small problem: 20-0767A

• Help prevent small problems from growing into large ones

• Any warranty issue: – Customer suffers (down machine)– Company’s reputation suffers

Big problem: 93-0397

103103

What should you do if you find parts What should you do if you find parts that will not workthat will not work

104104

Reject HandlingReject HandlingRED TAGS

Red tags identify parts or subassemblies that are damaged

or out of specifications and cannot be used for production.• If you believe a batch of parts is bad, reject them all!

105105

Downstream Effects-Downstream Effects-Failures lead to: Failures lead to:

• Unhappy customers– Internal– External

• Warranty/service costs

• Bad ReputationREMEMBER: PASS ON ONLY GOOD PARTS!

106106

Preventative MaintenancePreventative MaintenanceBefore starting to run parts Before starting to run parts alwaysalways verify that the verify that the scheduled maintenance is up to date on the machine! scheduled maintenance is up to date on the machine!

Did you know that you can set maintenance message reminders in the Haas control?

107107

Report any unusual conditions Report any unusual conditions

• Noise

• Chatter

• Alarms

• Poor tool life

• Material issues

• Deflection

• Etc. It is unacceptable to ignore any of these issues

108108

Section 7Section 7

Competitive EdgeCompetitive Edge

During productionHaas uses some of the most

advanced manufacturing techniques

109109

• Worldwide, many manufacturers are doing the same thing we are

• So, what makes our machine shop unique?

110110

Competitive Edge: TechnologyCompetitive Edge: Technology

• We use the most advanced techniques for all steps of the manufacturing process!

• Using advanced technology gives us an an advantage over the competition

! ! !! ! !

111111

ProbingProbing• Use the machine to set up

tool and work offsets.• Allow the machine to

determine what fixture and/or parts are loaded.

• Eliminate inspection steps by using the machine to inspect features.

• Reduce chance of crash since there is less human interaction.

112112

RoboticsRobotics• Automatic loading is more

consistent and can run “lights out”

113113

FMS (FMS (FFlexible lexible MManufacturinganufacturing SSystem) cellsystem) cells

• Flexibility and lights out capacity • Multiple machines fed by pallet racking system allows for

many different parts to run with minimal setup time

114114

Most Advanced Cutting Most Advanced Cutting ToolsTools

• Constant improvements are being developed by cutting tool manufacturers

• Chances are that there is a better, faster tool

• Haas uses the newest and most productive tools to find a “better way”

CUTTING SPEED

115115

Cutting Tools: Precision Ground Cutting Tools: Precision Ground Drills! Drills!

Eliminating slow and unnecessary center drills leads to greater efficiency

116116

Hydraulic fixturesHydraulic fixtures• Automatic

clamping of parts increases consistency and reduces labor

117117

5-side machines5-side machines• Single setup clamping to

machine a part complete

118118

SoftwareSoftware• The most advanced

design and programming software is used to streamline computer work

119119

Software: SAPSoftware: SAP

OVERVIEW

• Inventory Control

• Advanced Planning Optimization

• Bills of Material– Revision Control

• Scheduling

• Labor Efficiency

SAP is a computer system (Software) that gives Haas a framework to turn internal knowledge into a competitive advantage

SAP stands for: Systems, Applications, and Products

120120

Software: SAPSoftware: SAP

MRP / ERP• Powerful Computer

Program• Tells us when to

order more parts• Ties departments

together• Powerful engine for

Enterprise Resources Planning

How can I challenge myself to learn more about SAP?

121121

Continuous Training: Why Continuous Training: Why You are Here TodayYou are Here Today

• Training is also a priority at Haas

• Benefits YOU and the company

• Ensures consistency and uniformity

• Increases quality

122122

Technical Understanding Technical Understanding • Use of 3 point

locating to ensure accurate flat planes

• Forces involved in clamping parts and cutting chips

123123

Section 8Section 8

Review

124124

ConclusionConclusion• Our shop’s

size and production is amazing!

125125

ConclusionConclusion• Safety is a

priority at Haas

126126

ConclusionConclusion• Work “flows” both

internally in the shop and also through the other departments like purchasing, inventory, assembly, and shipping

127127

ConclusionConclusion• Parts like 20-7016c

start as a blank bar before moving through the shop, then end up as part of a finished machine in assembly.

• We have well-defined processes!

128128

• Critical parts are checked to ensure proper functionality.

Know what is critical!

129129

ConclusionConclusion• Be aware: what you

do in your area has an effect on the next area “downstream”.

• You can help catch little problems before they grow into big problems

CHECK YOUR PARTS!

130130

ConclusionConclusion• We use the most

up to date, efficient, and productive technology in every step in the manufacturing process

131131

Constant improvement: Your ideas Constant improvement: Your ideas are important! are important!

• THINK! • B-bigger• B-better• F-faster• L-less • E-expensive• Submit your

ideas to the BBFLE team

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How Do We Do It? The How Do We Do It? The Haas Way:Haas Way: • There is nothing we can’t do.

• We work as a team to accomplish goals.

• We take responsibility.

• We work hard and smart and always improve.

• We are passionate about our company.

• We never forget our customers or competitors.

• We fix problems.

133133

Conclusion: Conclusion: Take Pride In Your WorkTake Pride In Your Work

• Performance

• Reliability

• Innovation

• Diversification

• Exceptional Service

134134

Thank YouThank You

135135

TESTTEST

136136

Question 1Question 1• What is Haas culture?

• The “Haas Culture” is the underlying force that has brought us to where we are today.

• Positive characteristics to our culture:– We are driven to

succeed. – We are professional

in our conduct.– We measure our

results.– We think globally.– We act locally.

137137

Question 2Question 2• Why does Haas

continue to invest in new technology?

• Although the newer methods may be more expensive initially, they will be more efficient in the long run

138138

Question 3Question 3• Why is it important to check your parts?

• You can help catch little problems before they grow into big problems

CHECK YOUR PARTS!

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Question 4Question 4• What is a mating surface and why are they

important?

• Mating surfaces are where 2 parts join together. They are important because if the surfaces are damaged the assembled parts may not pass a quality check.

140140

Question 5Question 5• What determines how you should check

dimensions?

Blueprint tolerances

• General rule of thumb- measuring tool should be 10x more accurate than the tolerance you are checking

141141

Question 6Question 6• What is the most basic thing to remember

with safety?

1. Common sense shall prevail!

2. Avoid hazardous situations and minimize risk

Use Your Head!

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Question 7Question 7• Why is it important to keep fixtures in good

condition?

• Parts that are not clamped securely can be dangerous, and can also cause quality problems.

Regular maintenance should not be ignored

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Question 8Question 8• Who are your

customers?

• How can you make sure your customers are satisfied with what you provide them?

(Discussion)

144144

Question 9Question 9• What can you do if you have an idea to

increase quality, increase efficiency, reduce cost, or improve a process? (Ideas that better the companies’ operation)

Submit your ideas to the BBFLE team

Prepared by Jeremy Kermit

Haas Master Apprentice Graduate

Haas Automation

Machine Shop

2800 Sturgis Rd

Oxnard, CA 93030

Machine shop101 rev_l

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