If you've looked at our past posts or investigated our real world machine shop software products, you know that our feeling is that today's shop floors are TOO complicated ... plain and simple. Of course there certainly are instances and requirements for the complex ... but our feeling is that the 90%-95% of shops operating in the "real world" could be slimmer, trimmer, less complex ... all leading to more efficiency.
In this post ... our thoughts on an EFFICIENT shop floor.
The most efficient shops I have visited and worked were the shops where everyone pitched in to do every task. There was no set "programmer" for the CNC's ... maybe a lead person ... but every operator wrote their own programs and every operator performed their own set-ups. The lead person was the guy you went to when you had a problem you couldn't solve. But, for the most part, you were responsible for your machine. From getting it programmed to setting it up to run to making sure it ran efficiently.
In my opinion those shops were efficient. No bottlenecks waiting for the "programmer" or the "set up guy". I also feel those employees felt empowered and in control of their jobs and their futures. They also felt their employers trusted and respected them and this was the key to putting that "people power" in motion.
But ... How to accomplish this is today's environment?
Most importantly is to provide the floor with the tools they need to be successful. From our perspective ... at least one PC and probably more is a definite requirement. Load that PC with "real world" software that can assist in programming and with shop floor calculations that personnel need every day. Trig functions ... speeds and feeds ... formulas ... calculations like SFM to RPM and others. Much time is often wasted seeking answers in these related areas and frustration can build when trying to track them down.
Software such as our Kipware® conversational to assist with the creation of the "everyday" CNC programming. Software that is easy to understand and implement and can quickly and easily create efficient CNC programs for those everyday simple drilling, milling, turning and threading type applications.
G code conversion software that can automate those everyday edits and tweaks that are often required due to actual cutting conditions. From the simple but time consuming tasks such as ... reducing all feedrates by 5% ... increasing all RPM by 10% ... subtracting 2.00" from all X dimensions too the complex task of auto-converting a G code program written for one machine and control to operate on a different machine and control. Without having to re-post and funnel the job back through programming means faster print to chip time.
PC based training and reference software where users can find answers to programming questions. Even if someone just wants some clarification about how a specific G code works. PC based training and reference software like our KipwareEDU® is a perfect addition to any shop floor PC.
These types of tools can help increase efficiency by further empowering the shop floor personnel without a major outlay in terms of costs. Putting answers and solutions at the fingertips of your shop floor personnel certainly means more efficiency and more opportunity to succeed in all areas.
How about your shop floor?
Have you taken a good look lately?
Have you tried empowering ... re-training ... cross training ... to make an efficient workforce?
Have you really gauged the skills of your workforce and placed them in the positions to succeed both on a personal level and for your company?
Come on manufacturing ... We can do this !!!
Kenney
