Fastems At EMO Hannover 2023 – World’s Leading Fair for Production Technology

From September 18 to 23, 2023, EMO in Hanover will once again be the meeting place for experts in the metal cutting industries. Meet the biggest names of the machine tool building and precision tooling industry as well as leading experts in metal cutting!

Take the opportunity to discuss the optimization of the productivity and manufacturing process with our CNC automation experts at our booth D67 in hall 12.

Experience live:

Ethernet Vs Wireless

In this day and age, there is almost an expectation that everything could (or should) be run using a wireless (Wi-Fi) connection. Whilst Wi-Fi provides a level of convenience it has its downsides, particularly in industrial environments. There are still many benefits to using Ethernet cabled connections, however, as we will outline in the article below.

Speed

The strength of Wi-Fi connections can vary based on environmental factors, which can have a major impact on the network speed achieved. Wi-Fi signals may encounter limited coverage over long distances, especially through walls or obstacles, or bandwidth congestion when multiple devices are connected. Ethernet networks, however, maintain a consistent connection speed up to 100m and, if shielded cabling is used, are suitable in industrial facilities.

Reliability

Wi-Fi is prone to drops, or in some industrial areas cannot reach the highest speeds required for decent performance. Hardwired connections are far more reliable, with each Ethernet connection representing a dedicated full-speed line with lower latency. Ethernet connections are not subject to interference from other devices or environmental factors, providing a more consistent and reliable network performance.

Security

An Ethernet connection has far better security than a Wi-Fi connection. Unless someone can physically attach a device to your network there is no way for anyone to breach your data. Data on a Wi-Fi connection travels through the air and can be captured more easily. This emphasises the importance of having a clear security policy governing the devices that can connect to your network.

Ease

With time always of the essence in the current climate, another major benefit is how easy cabled connections are to set up; the user simply has to connect an Ethernet cable from one socket to another! There’s no confusion regarding specifications – most Ethernet links use standard RJ45 connectors.

Whilst Wi-Fi is great for domestic and casual purposes, where the majority of services used are web-based, an Ethernet connection triumphs over Wi-Fi for accessing data locally on a network – particularly in an industrial environment. With the speed, reliability, security and ease of connection that it offers, it really is a no-brainer!

TECHNOTURN’S AMBITIONS UNDERPINNED BY LONG TERM PSL DATATRACK SUPPORT

Technoturn Ltd, the southern division of Techno Group, are a manufacturing solutions provider based in the South East of England. Specialising in high precision CNC machining and assembly, Technoturn supply into some of the world’s leading developers of cutting-edge technology across a spectrum of industries including aerospace, defence and scientific research.

From humble beginnings as a supplier of small turned parts, Technoturn now boasts 35 CNC machines ranging from small diameter lathes to full 5-axis machining centres, producing highly complex components from both raw and profile materials. The machining capabilities that are housed in their 16000 sq. ft. facility are complemented by in-house mechanical assembly and surface finishing operations that are project managed from site, meaning that Technoturn are considered a ‘one-stop-shop’ to many customers.

In 2001, Technoturn saw a rapid growth in demand from new and existing customers with intermittent purchasing behaviours and an increased demand for small-batch production. Rather than employing extra administration staff to manage the increased commercial and administrative requirements, the company chose to introduce a bespoke PSL Datatrack solution, designed specifically for the subcontract precision engineering industry.

PSL Datatrack was selected for its modularity and ability to be readily adapted to meet the changing requirements of Technoturn and its customers. The modular structure of the software allowed the company to only pay for the functionality that was needed to improve the production and administration of the business at the outset, without the burden of increased costs incurred by an overblown system containing unnecessary functionality.

Inevitably, in such a dynamic business, there are always complications and changes to working practices. Over the years, PSL Datatrack has worked with Technoturn to support its rapid growth, tailoring its service to assist with managing key company activities including production planning, purchasing and invoicing. This has ultimately helped to control the company overhead whilst keeping administration time and costs to a minimum. The nature of the system results in seamless introduction of new modules, with training from PSL Datatrack provided to help Technoturn utilise them as quickly as is practical without disruption to the day-to-day running of the business.

Technoturn initially used PSL Datatrack to prepare quotations and process works orders. Modules added later include Invoicing and Purchase Invoicing, Bill of Materials (BOM), CRM/Tasks, the Sequential Scheduler, Shop Floor Data Collection (SFDC) and Gauge Management. Also added was Non Conformance, which manages and monitors both works and supplier non conformances, providing a detailed history of all rejects.

PSL Datatrack is now utilised across every department within Technoturn and is the key to all business activity. “Datatrack is a logical choice for an SME. It is an auditor’s dream – all supplier, material and process certifications are easily accessible through Document Management, which also significantly increases efficiency when dealing with client queries. As our business evolves, PSL Datatrack gives us the ability to bolt on new modules as and when required,” comments Dan Wahnon, Technoturn Business Development Manager.

Each module has its own benefits to Technoturn. The Sequential Scheduler allows the company to publish guide schedules for production and uses simple colour coding to highlight potential bottlenecks. Combined with the SFDC module, Technoturn is able to use PSL Datatrack to determine whether production deadlines are being met, if quotations are accurate and whether each cost centre is generating target revenue. All modules are frequently upgraded as part of an annual software release and can be tailored to the customer’s specific needs through variable configuration options.

Technoturn’s working relationship with PSL Datatrack does not fit into the traditional customer/supplier model. The PSL team is considered one of Technoturn’s most valued partners and has worked, over the years, to customise existing reports or develop new ones that are not part of the standard system. This service is crucial in order to keep up with the company’s digitalisation process and the ever-changing nature of Technoturn’s business. “We are always looking to extract and present data in new ways to progress on our journey of continuous improvement. We very much rely on the flexibility that working with PSL provides us with,” says Dan.

The Supplier Scorecard, a customised monthly performance report for each supplier, gives both Technoturn and their supplier the ability to evaluate performance over various time periods. The data provided can cover areas such as the number of lines delivered, the number of lines late and the number of supplier non conformances. There is a ‘percentage on time’ figure and a ‘percentage quality by delivery’ figure, with colouring dependant on each percentage threshold. Sourcing decisions are then made based upon how well a supplier performs.

Status Boards are the next offering from PSL Datatrack technology being considered by Technoturn and are already installed in other divisions of the Techno Group. Dan will assess their benefit in providing real time, visual data regarding current production, shop floor instructions and performance against key performance indicators (KPIs).

PSL Datatrack is an invaluable tool that supports and contributes to the health and long-standing relationships across the Group’s worldwide customer base. Maintaining AS9100 quality standards, the Techno Group drives supply chain efficiency, component consistency and reliability whilst constantly striving to improve its reputation and diversify services. This has been highlighted by continuous investment in new software and machinery despite the significant challenges experienced across the manufacturing industry as a result of the Covid-19 global pandemic.

The Group’s mission is to be the first-choice manufacturing partner for all customers, past and present. “We strive to set the example for engineering excellence in everything we do by investing in our people, processes and capabilities, allowing us to apply innovative manufacturing solutions that exceed customer expectations.”

“PSL Datatrack continues to help us meet this promise. Their service is invaluable to us in subcontract manufacturing, not only meeting our specific requirements but also those of our clients. Each business relationship has unique nuances that need to be accommodated,” concludes Dan.

For more information, visit www.psldatatrack.com or contact PSL Datatrack, Lily Hill House, Lily Hill Road, Bracknell, Berkshire, RG12 2SJ, Tel: +44 (0) 1344 827312, Email: sales@psldatatrack.com

Removing Manual Repetition With PSL Datatrack

Manual repetition and data entry are common pain points among subcontract precision engineering businesses.

We, at PSL Datatrack, have seen many variations in the manual processes subcontractors will go through because their fundamental purpose is to produce components, not to design systems. Our system is there to streamline the entire production process, from quotation to invoice, for them.

The system was written with the knowledge of that process in mind, therefore speed and ease of use are key. PSL Datatrack starts with a quotation; we describe our Quotations module as the production control software equivalent of setting a machine tool! Once the information has been entered at this stage, it can be reused throughout the rest of the PSL Datatrack system to prevent the manual retyping of data, human error and to help get the paperwork done as quickly as possible.

The Quotations module is designed for how subcontract precision engineers need to work. There’s no unnecessary information or extra boxes to populate – it’s all tailored directly for them. The quote is commercial and calculated by defining the process (set and cycle times), material, subcontract and tooling requirements alongside any mark-ups.

They also need to have control over tailoring the quotation – for example, larger batch sizes may be calculated at a preferential rate. It’s all about being able to quickly make those changes to ensure the quote is fully accurate and PSL Datatrack caters for all of these factors. If a customer has a unique requirement we can also write bespoke solutions.

Producing a quotation, if you don’t have a designated, organised system, is often going to be done on an Excel spreadsheet. But what happens to the data after that? It’s there for a calculation, yes, but it doesn’t go anywhere else.

As well as calculating the sales price, PSL Datatrack enables the user to produce a well formatted and well presented quote letter at the push of a button, which can be sent to the customer with minimal effort. A PSL Datatrack quote letter is displayed as the user wants it – it’s their way of presenting themselves to the customer, after all. If you have to type up letters on Word documents or emails it can take a huge amount of time.

Likewise, before taking on PSL Datatrack some of our clients used Word to create their job cards. So, they’ve already done a manual quote in Excel – they then had to re-key that information to get it into the Word document. That Word document is an order, potentially, but then they needed a separate spreadsheet for their order book. Then they needed to produce a delivery note, which may be yet another manual document or require entry into their accounts system. PSL Datatrack, however, pulls all existing data through to the next stage for the user.

The system automatically creates all documentation, through to final invoice, which can then be generated with company letterheads and emailed to customers straight from the system. All financial data can then be imported into accounts systems with no rekeying required. All credit control is therefore dealt with externally, with all document generation and traceability dealt with in a specialist production control system.

When taking on a PSL Datatrack system, users may wish to import existing data to kickstart the process. PSL Datatrack can comfortably handle this and we will always agree which information they would like to start with. This means there is no need for someone to sit down and key in all their customers and suppliers, for example.

As well as documentation, PSL Datatrack includes many detailed reports within each module that focus on all business areas. For management, there is also a statistics screen which brings up to 57 key performance indicators (KPIs) together on one screen to give you a high spot of all the different areas. Users can click on any of these statistics to generate a report with all the data behind it. There is no need to create manual dashboards or management reports as the system does it for them.

As PSL Datatrack is a practical, simple and logical system we don’t usually get involved in training when customers take on a new employee, although we always offer training as part of new system implementation. There tends to be enough skill within the company that they can train new staff themselves. With a bit of practice, they’re typically up to speed and productive very quickly.

PSL Datatrack is therefore integral to the whole business as soon as it is installed. Production control software runs the company, gives management control and ultimately shows them what needs improving. Make the first improvement today by contacting PSL Datatrack!

5-Axis CNC Machining, The quality you need – the prices you deserve.

Check out our latest feature on PBE CNC Ltd, a top-tier machining company based in Havant, UK! Our technical reporter Tom Skubula spent a day in their facilities and was blown away by their ability to manufacture parts quickly, reliably, and with unbeatable accuracy. With a new 5 axis machine and the introduction of hyperMILL, PBE CNC has taken their production to the next level, making the process of creating parts from drawings to completion faster and more efficient than ever before. Plus, the surface finishes and overall product quality have never been better. Don’t miss this incredible success story!

The past, present, and future of the pioneers in cutting fluids

Tony interviews David Barned, Senior Vice President & General Manager of Master Fluid Solutions, to find out more about the 70-year-old metal-working fluid business and its growth into the future. As pioneers in the industry, Master Fluid Solutions know what difference metalworking fluid can make in the machining world. From it’s first synthetic formulas and emulsions to new kinds of technology, Master Fluid Solutions is focused on making products that are safe for people, machines, and the planet. The truly global company has a distribution network around the world to help customers get products in time. They work to develop both the cutting side as well as the environment and people-friendly non-cutting functions such as foaming issues. Master Fluid Solutions have over 100 formulas and offer customised solutions based on the needs of customers. Find out more from David on eco-friendly solutions and how the correct cutting fluid can help you save BIG on tool life, among other facets of manufacturing.

£4.50 just for the material, would you risk it?

An amazing story about a company transitioning their business and making this part on one machine instead of two and when you hear the cost of the material you’ll understand the reason they needed a reliable machine to make the part to tolerance in one-hit.

hyperMILL is smoother, it’s slicker and it does more!!

Matt Coulson from OPEN MIND accompanied MTDCNC to Hi Spec Precision Engineering a new user to hyperMILL. Having recently taken delivery of a new MX-330 from Matsuura, Darren was in search of the best CAM software to drive it.

 

That part is tiny, how do you turn that?

How do you go about turning parts like this? And not just turning them but maintaining tolerances without having to continually inspect the parts. Rowan is at GA Engineering in Scotland to find out how!!

Machining centre productivity up 5-fold due to automation and operating costs much lower

Robotic component loading and unloading is helping prismatic components subcontractor Hemlock Engineering, Stapleford, to unleash the true productivity potential of its latest Brother 5-axis, 30-taper Speedio M200X3 vertical-spindle machining centre (VMC). The result has been a 500 percent increase in production output compared with manually-loaded machines on-site.

The remarkable aspect of this automation success story is that it has been achieved in the most problematic of scenarios, i.e. the production of relatively small batches of components between 1,000- and 2,000-off requiring short cutting cycles of between two and 10 minutes, a combination that necessitates frequent changeover of the production cell.

Hemlock’s owner Paul Cobb had exact figures to hand when interviewed. He said, “Typically, one of our 40-taper VMCs runs for 40 hours per week. However, a lot of the time the relatively slow spindle is not cutting – I estimate we get on average 45 percent utilisation. With the robotic Feedio load / unload system serving the latest Brother, we achieve 100 hours operation per week, sometimes more, and the uptime of the faster 30-taper spindle is 88 percent.

“On this basis, overall production output is about five times that of one of our 40-taper machines. Additionally, the latter capacity needs the full-time attendance of an operator whereas the Brother cell occupies an operator for only about 20 percent of the person’s time. So there is a five-fold reduction in the labour cost content of components produced.”

He explained that the plug-and-play Speedio / Feedio cell costs about £800 per week to run including finance, labour and power, which he said “is not very much”. It arrived on the shop floor in March 2022 and, as already observed, produces similar output to five 40-taper machines with full-time operators. That is why Mr Cobb describes the benefits of his first ever automated prismatic component production cell as “absolutely astronomical” and “off the charts”.

What makes automation feasible for small batches of relatively uncomplicated components requiring short cycle times is rapid cell changeover within two hours, including swapping the cutting program and tools. It is largely down to Brother’s easy-to-use ChipLite conversational software that controls the handling robot and camera vision system.

All that is needed is to key in via a touchscreen GUI the size of the new raw billet, the spacing on the conveyors and the gripper finger data. Connection of the robot program, generated by the dedicated on-board PC, to the VMC control system is via a Profibus link. Mr Cobb asserts that changing over a conventional robot-loaded machining centre and reprogramming it would take days rather than hours.

There are other makes of 5-axis VMC in the Stapleford factory, all 40-taper models. The Brother M200X3, with its 300 x 440 x 305 mm working volume and 16,000 rpm face-and-taper contact spindle, is the first 30-taper 5-axis machine on-site, the other eight Speedios being 4-axis models with a rotary indexer.

The effect of having an additional CNC axis on the M200X3 and using the machine in 3+2 or 4+1 positional mode is to deskill machine operation. It also reduces fixturing costs and balances more closely the machine’s cutting cycles with the time required for performing a second operation manually on another machine to finish the sixth face of components.

What tends to happen in practice in Stapleford is that foreman Rob Sinclair sets up the Speedio / Feedio cell when he arrives on Monday morning. It then runs for typically two days non-stop, virtually unattended, before it needs to be reset. It is the inexorability of component loading and unloading without any stoppages that Mr Cobb says underpins the cell’s very high efficiency and production output.

He also advised that every night shift in particular is much more productive with the automation, as all the operator needs to do is attend to swarf clearance, tool exchange and perhaps coolant supply. He or she is therefore free to complete other duties on the shop floor with very little interruption.

As to his choice of automated handling of the component itself, rather than a machine pallet with a component fixtured, Mr Cobb points to the couple of hundred different jobs routinely passing through his factory that are able to benefit from automation. They would need expensive pallets and bespoke jigs and fixtures, a production route that would not be economical. Furthermore, the footprint of such pallet change systems tends to be large.

It is interesting that in 2014 when Hemlock Engineering, 90 percent of whose production involves machining aluminium, took the policy decision to migrate from 40-taper to faster 30-taper machines, the subcontractor gained the productivity boost that it was seeking due to cycle times that proved to be between 50 and 70 percent quicker than previously. However, what was not foreseen was that the Speedio machines would be so fast that one operator was committed full-time to each, so there was no labour cost advantage. It is exactly this problem that robotic loading and unloading solves.

In the first four months of operation, around 25 different components that were previously produced on 3- and 4-axis VMCs had passed through the automated Brother 5-axis cell. The jobs were about to start repeating, with the prospect of even greater gains the second and subsequent times a batch of components is produced.

The benefits of the production solution were so conclusive, including the small footprint on the shop floor and the low power consumption, that Mr Cobb almost immediately placed an order for a second identical cell, which is due for delivery in December 2022.