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Marketing in a Time of Crisis

Over the last few months, I’ve had the opportunity to watch our clients react to the virus and adjust their businesses accordingly. As all our clients are manufacturing enterprises, they’ve needed to adjust their production scenario. Several innovative clients have gone from 1 to 2 or 2 to 3 shifts to achieve proper social distancing with no decline in the output. Most clients have returned to work in the office, as of this writing. Three clients have radically increased their ad spending, with one quoting me my own line, “Smaller pie, bigger slice.” He remembered 2009, all too well. The big difference here, of course, is that the current slowdown has absolutely NOTHING to do with economics.

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Social Media — A Valuable Marketing Tool During COVID-19

By Maureen Lepke

All industries are feeling the effects of Coronavirus. Manufacturing and industrial companies are not an exception. So what can you do in a time where trade shows are cancelled, everyone is working from home and trying to find new ways to get their company’s message out? The answer is social media. Social media is a low-cost, yet valuable marketing tool that allows your company to talk to your customers every day throughout the month.

What’s the benefit of having an agency do your social media for you? We have a full-time social media director here at the agency and we are strictly industrial so we understand your world. We are consistently posting 5 days a week. Social media is usually the first thing that slows down when a company gets busy. It becomes an afterthought when social media should be a critical part of your marketing strategy.

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Smaller Tool Manufacturers Take Advantage of Breakthroughs in Industrial Automation

By Duncan Thompson, ANCA Product Manager

ANCA's CIM3D Simulation Gives Automated Collision InformationIndustrial automation is changing the way cutting tool manufacturers operate. Machines have taken on the heavy lifting at each stage of production letting workers get on with less repetitive tasks. And while automation may sound costly and complex to implement, it’s not reserved just for just big business. There are dozens of ways a small cutting tool manufacturer can embrace automation for a more efficient and more innovative factory.

What are the benefits of industrial automation?

  • Cost reduction, through labour costs or machine uptime. The drive for automation is being driven by availability of skilled labour, where and machines can fill those gaps.
  • Automation is an important step to help people meet regulatory obligations with relation to the limits of weekly work hours without compromising machine utilisation.
  • Reduced material handling makes run smaller batches much more cost effective.
  • Streamlining of existing processes and systems across the business.
  • Eliminating mistakes in material management.
  • Automating in-process measurement raises the quality of tool production and can nearly eliminate waste, meaning more profit.

Don’t invent; stand on the shoulder of giants
It’s true that bigger companies have more buying power. When it comes to industrial automation, they have plenty of scope to ask for tailored developments to suit very specific needs, or to make these adjustments in house. But as new technology and solutions are developed in response to these requests, the industry as a whole will benefit.

Just because a technology is off the shelf, doesn’t mean it is ‘standard’. In fact, our industry is constantly evolving as new solutions are found and applied. While their technology development may have been developed at the request of a large customer, as soon as it’s scalable it can be rolled out to suit most businesses. At ANCA this includes many of our innovations including 3D simulation software, our in-process measurement system Laser Plus, and RoboTeach, which makes robotic loaders accessible and easy to program.

ANCA's Roboteach SolutionThe addition of laser etching on a Robot loader is another example that has increased the functionality of the grinding machine by including what would otherwise have been additional downstream steps in the process of making tools.

As a small tool manufacturer, vendors recognise that your priority is maximising your factory’s efficiency – machine uptime versus setup time. They know that you need software and accessories that will help you keep things ticking over without wasting time and money reloading materials.
ANCA's LaserPlusHow do you approach where to start?
Chances are there will be no obvious trigger when it comes to adopting industrial automation. Many smaller businesses won’t have planned to develop the level of automation they have. Some may have started only after an increase in labour and setup costs forced them to look for ways to run more smartly. But that is ok, you can build your automation solution piece by piece – as long as you have an agreed vision.

It may be as simple as being observant and seeing which steps in your production process have the greatest cost. Unlike other efficiency drives there is no harm in approaching this piecemeal. Start by attacking the area of your business that will provide you with greatest value. For instance:

Look for industrial automation solutions that reflect how you operate
At the smaller end of the tool cutting market there’s a good chance you’re producing small batch lots and changing geometry multiple times a day, rather than leaving the machine running constantly making the same tool all day.

In this world innovation is often a secondary need to maximising day-to-day productivity. For instance, look for solutions that allow the operator to step away from the machine and carry out other tasks, rather than being there all day. Automating geometry changes and your existing manual material management processes can make a real change to how much they are able to do elsewhere and help you maximise machine uptime vs setup time. Time is, after all, money.

Automate production but also consider automating processes
You may not have the business budgets to request tailored solutions, but out-of-the-box solutions are available that can be used to manage inventory, integrate with your ERP to manage job order, and even pack ready for dispatch. Many will work effectively with your existing processes, even if you have never automated them before.

ANCA's AutomationIndustrial automation can keep your focus on people
A small cutting tool factory relies on every working part being up to scratch – and that includes your people. Automation removes the risk of human error creating a safer working environment that’s less likely to be disrupted. Furthermore, changing government legislation is limiting how many hours employees can work. Automation is the obvious solution to maximise machine up time when people are not present.

Applying industrial automation solutions that connect you more to your customers will allow you to see in real time what they’re low on, what’s in high demand, or what’s coming up in your production that will suit their requirements. This allows you to explore other areas of production and manufacture tools knowing with confidence what your customers want.

Everyone can afford and benefit from existing industrial automation solutions
Automation can take the pain out of being a small tool shop. Your new factory of the future will be able to produce multiple kinds of tools without getting bogged down in manual operations.

We can all benefit from streamlining systems and processes. Focus on your speciality and leverage the tech that’s already out there. There are better ways for you to use your time. Grind the wheel, don’t reinvent it.


Duncan Thompson is a Product Manager at ANCA, responsible for the technical direction and commercialisation of new machine and application developments. Having been at ANCA for over 22 years, Duncan has gained intimate market and grinding application knowledge by working across a range of roles including service, application grinding, sales, special project development and marketing roles. As a fluent Japanese speaker, Duncan was based in the Japanese market for three years and retains strong ties to customers in that unique market. Today, Duncan’s motivation and passion in the Product Manager role comes from “working with customers from diverse international markets to understand their challenges and being instrumental in delivering solutions.

 

For further information, please contact:
Sepideh Zandieh
PR and Communications Manager, ANCA
M: +61 439 316 131
Sepideh.Zandieh@anca.com

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Exact Metrology Reverse Engineering Final Product

Exact Metrology Showcases Potential of Reverse Engineering

Exact Metrology Reverse Engineering CT ScanGreenery 33 is a company in Cincinnati, Ohio that produces creative and unique plant holders and pots.  The company donates 33% of their earnings to environmental protection agencies. One of Exact’s engineers is friendly with Greenery 33’s owner, so Exact Metrology participated in a marketing campaign aimed to show the process of reverse engineering and how it can used with various materials.

Exact Metrology Reverse Engineering Plant HoldersThe first step was to scan and have a digital copy of a physical skull.  Secondly, the skull was reverse engineered using Geomagic DesignX software and NURBS. Geomagic is a leading provider of 3D software to create digital models of physical objects for industries such as: archaeology, aerospace, medical and dental, tooling, foundry and sculpture and arts. The Geomagic Design X combines history-based CAD with 3D scan data processing, enabling users to create feature-based, edible solid models compatible with existing CAD software. NURBS, or Non-Uniform Rational B-spline is used to represent curves and surfaces. Next, surface analysis is performed with Geomagic Design X for parametric modeling. Afterwards, NURBS is inspected with a color map against the scanned data of Geomagic. Lastly, .stl files rendered in Keyshot 3D of the skull are placed in product shots for Greenery 33.

Exact Metrology Reverse Engineering Final ProductThis process took two days. By using reverse engineering, Exact Metrology showed Greenery 33 an efficient and cost-saving way of working with materials like plastic, glass and ceramic without physically reconstructing it.


Exact Metrology is an ISO 9001:2008 and AS9100 Certified Company 

Exact Metrology, with facilities in Cincinnati, OH, Moline, IL and Milwaukee, WI and affiliated offices throughout the country, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings.   The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

Exact Metrology offers a complete line of portable scanning and measurement technologies as well as contract measurement for 3D laser scanning services, reverse engineering services, non-contact inspection, metrology services, and 3D digitizing. The company’s newest equipment includes a CT Scanner, the first in America being used for metrology rather than medical testing. Exact sells and rents metrology equipment solutions, in addition to providing testing as a service and application software training.

 

For information, please contact:

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Local: 262-533-0800
www.exactmetrology.com
deans@exactmetrology.com

 

EXACT METROLOGY, INC.
Steve Young
11575 Goldcoast Drive
Cincinnati, OH 45249
Local: 513.831.6620
Toll Free: 866.722.2600
www.exactmetrology.com
stevey@exactmetrology.com

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Grieve New Website

Leading Manufacturer of Ovens & Furnaces Launches New Website

Grieve New WebsiteThe Grieve Corporation, experts in industrial manufacturing of ovens and furnaces with a long history of 70+ years, launched an updated website with new features and enhancements to existing capabilities.

“As our company continues to grow, we look for our new website to offer the digital tools necessary to better serve our customers,” said Tony Caringella, COO.

The website details Grieve’s entire selection of ovens and furnaces in a digital catalog that is easy to navigate. With hundreds of different models, customers can help narrow down the right equipment for their process by utilizing the oven finder tool by applying filters such as workspace area, operating temperature, loading method and more. Although the company offers hundreds of standard models, Grieve also has unique customization abilities to engineer the best equipment for one’s application; the site details many custom ovens and furnaces as well.

Site visitors can browse Grieve’s selections of ovens and furnaces and submit a request for quotation; the viewer can find the equipment that fits their process needs, along with compatible modifications and accessories, and submit a message directly to Grieve for a customized quotation that can be tailored to a specific process or application.

Ordering replacement parts is made simple with the Ecommerce platform. Customers can search by part type to find parts needed for their equipment, and order directly from the website. The Grieve team will verify the item with the customer’s equipment to ensure compatibility.  Customers are also encouraged to create an account which will hold their information for ease of checkout for future purchases.

Grieve works with sales representatives throughout the country (as well as globally) to support customers that would like assistance at their workspace to determine the best equipment for their needs.  A local sales representative can be located using the Locate a Rep tool. Another resource for customers is the extensive resource library, housing hundreds of manuals, component literature, safety information, etc.


Explore these features, as well as additional information on all of Grieve’s products, processes, and services at www.grievecorp.com.

Contact info:

Allison Luber: (847) 546-8225
The Grieve Corp
500 Hart Rd, Round Lake, IL 60073
www.grievecorp.com

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Exact Metrology Helps Retrofit Aircraft

Exact Metrology, a comprehensive metrology services provider, recently completed a job at Chicago Jet Group. Located in Sugar Grove, Illinois, the company started in 2003 with the idea of providing the highest level of professionalism and attention to detail in the corporate aviation industry.  Chicago Jet Group specializes in aircraft acquisition, aircraft management, charter services, pre-purchase evaluation, aircraft avionics, aircraft consulting and aircraft maintenance. The company was retrofitting older Dassault Falcons avionics and needed a CAD model of the panel to see how it would fit.

Joe van der Sanden, application engineer from Exact Metrology, scanned the panel with an 85 series Hexagon Romer Absolute Arm. The Absolute Arm 7-axis delivers tactile probing and laser scanning in an ergonomic package. It is the best choice for ease of movement and ease of measurement. The flagship RS5 laser scanner offers high-speed 3D scanning Retrofit Aircraftfor surfaces and features on a wide range of finishes and materials with less investment than the RS6. Furthermore, the RS5 laser scanner boasts a wide and horizontally-oriented laser scan line and fully-automatic exposure settings, making general purpose scanning functionality simple to apply regardless of application. In addition, with mid-range width at 115 millimeters, the laser scanner line of the RS5 makes digitizing large surfaces simple and quick.  The RS5 can be easily removed from the arm, allowing simpler and safer access to touch probing functionality in hard-to-reach areas. Thanks to repeatable mounting, it can be remounted without recalibration. Through the on-wrist OLED display screen of the Absolute Arm 7-axis, the RS5 allows for measurement feedback and settings adjustment at the point of measurement for a clear improvement to workflow productivity.

Then, dimensions were obtained in Polyworks Inspector. The Polyworks software suite covers the complete product development cycle, from part and tool design and prototyping down to final inspection of assembled parts. Polyworks Inspector™ is the industry-standard toolbox for product engineering, assembly guidance and final inspection.

Reverse engineering was performed using Geomagic Design X. This software combines history-based CAD with 3D scan data processing and enables the creation of feature-based, editable solid models compatible with existing CAD software.  Geomagic Design X allows users to re-use existing designs without having to manually update old drawings or re-measure and rebuild a model in CAD. This software is easy to learn and use, for it uses familiar history-based tools found in all major CAD products.

Chicago Jet Group was very pleased with the work performed by Exact Metrology and they would be happy to work with them again.  A senior avionics technician at the company said, “This will save us months of measuring and drafting.”


Exact Metrology is ISO, AS9100 Certified as well as FFL and ITAR Registered.

Exact Metrology, with facilities in Cincinnati, Ohio, Moline, Illinois and Milwaukee, Wisconsin, plus affiliated offices throughout the country, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings.   The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

For information, please contact:

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Local: 262-533-0800
www.exactmetrology.com
deans@exactmetrology.com

 

EXACT METROLOGY, INC.
Steve Young
11575 Goldcoast Drive
Cincinnati, OH 45249
Local: 513.831.6620
Toll Free: 866.722.2600
www.exactmetrology.com
stevey@exactmetrology.com

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ANCA Launches the New-Look CIM3D V9 With Time-Saving and User-Friendly Enhancements for Offline Productivity

A sophisticated analytical hub provides increased intelligence on cutting tool designs to avoid costly collisions and missed calculations

ANCA CIM3D Software advanced sectioning planeANCA’s new CIM3D V9 release of the industry-leading CIMulator3D software has an upgraded interface with fresh colors and icons and is even easier to use with intuitive functionality. The latest technology and software design has been packed into this release offering time-saving benefits and interactive visualization across the entire grinding process.

Thomson Mathew, ANCA Software Product Manager says: “This upgrade responds directly to what our customers want and need for effective tool simulation. CIM3D V9 allows for customization based on regularly-used features no matter which industry. The simulation quality of ANCA’s software is unmatched and you can simulate complete grinding sequences.”

“The offline capabilities of using the latest CIM3D version mean important background calculations are easily verified, increasing machine productivity. This not only maximizes machine time but for those working from home, CIM3D can be run independently on any computer – so it is possible to do all the programming remotely.”

“We have automated many manual steps and introduced process verification and analysis in a central hub to get improved cycle time, and better wheel and tool life. Collisions can be detected automatically and overall CIM3D V9 is more enjoyable and easier to use.”

The new software offers clearer visualization with the customizable timeline panel – effectively a central dashboard for quicker and easier tool analysis. New tool programs can be verified for size, shape, machine clearance, cycle time estimates, and more.

Chris Wagner, Tool Grind Lead at Acutec Precision Aerospace, Inc. in the U.S has been using CIM3D for 20 years and can’t imagine going back to an earlier version after trialling the latest release. He said: “CIM3D V9 is worth its weight in gold. The new look and feel is current and clean. One of the best features is progressive grinding – it gives the ability to see the exact material being removed as the wheel moves through.”

“The resolution of the graphics is far better than any previous version. Determining protrusion length, cycle time estimation, using the scroll function on a mouse to increment the position, magnification and cross-hair positioning are other great features that make using CIM3D V9 more efficient and productive.”

ANCA’s software experts are in-house ensuring the features of CIM3D are responsive, user-friendly and tailored to the cutting tool industry.

The new features save time while simulating the programmed tool path exactly as it would be ground on the machine

UPDATED LOOK AND FEEL

  • Brand new interface with new icons and color scheme
  • Better user experience and a modern look
  • Customizable toolbars
  • The animation toolbar has been replaced with a timeline

BENEFITS: Ease of use, improved visualization and highly intuitive design

PROGRESSIVE MATERIAL REMOVAL

  • Provides a realistic and unique view of the material removal process
  • Allows visualization of the grinding process during a move
  • Allows the visualization of the wheel imprint at any point of time
  • Allows better visualization of unexpected deviations in the wheel path

BENEFITS: Allows the user to view the state of the tool at any point of the grinding timeline

ANCA CIM3D V9 Progressive Grinding

CLEAR VISUALIZATION WITH THE TIMELINE PANEL

  • Provides an interactive timeline of the grinding process that acts as an animation and analysis hub
  • Acts as a central dashboard for all analysis rather than having it distributed in multiple places

BENEFITS: Central analysis hub for quick and easy access to save time

TOOL BALANCE ANALYSIS

  • Provides complete information about the balance of a rotating tool
  • The output includes the quality grade and imbalance of the tool
  • This information is then passed on to ToolRoom to balance the tool effectively

BENEFITS: Ability to manufacture high performance cutting tools

SAVE TIME WITH BACKGROUND CALCULATIONS

Simplifies workflow by doing calculations in the background rather than having users kick this off. This saves time and the automatic display doesn’t allow for errors that are accidentally missed. Some of the tasks calculated automatically without needing to be initiated by users are:

  • Collisions – these are recalculated automatically when machine configuration is changed
  • Material removal rates – calculated when row is shown in timeline to display the MMR graph
  • Tool balancing – Tool balancing is calculated automatically when tool balancing dialogue is shown

BENEFITS: Simplifies workflow, saves time, less likely to miss collisions and reduced waiting time

MATERIAL REMOVAL RATE

  • Provides visualization of the material removal rate (Q) value to visualize jump in feedrates and is useful to normalize feedrates
  • A chart is provided to visualize the material removal rate (Q)

BENEFITS: MRR can be used to optimize the feedrates for better wheel life and stable process

MEASUREMENT CAPABILITIES

  • Allows the placing of three points to measure a radius
  • Behaves like a 2D overlay – moves with the tool in translation, but not in rotation
  • Handles the same use case as a shadowgraph
  • Typically used to measure the cutting profile radii

BENEFITS: Quick and easy measurement methods to save time

CHANGES TO THE SECTIONING PLANE DIALOGUE

  • Multi-step sectioning plane orientations can now be viewed in the measurement view
  • Basic and Advanced dialogues merged into a single dialogue

BENEFITS: Flexibility to measure any geometry on the cutting tools in any plane

MACHINE MODELS AND ACCESSORIES

  • The ‘wheel changer’ tab has been renamed to ‘wheel and coolant’
  • Option for MX splash guard for better collision analysis
  • FX5 Wheel Changer added to detect collisions with changer gripper
  • MX and TX machine models have been updated to use the current color scheme (as per V8 updates)

BENEFITS: Additional accessories for improved collision detection analysis


 For further information, please contact:

Sepideh Zandieh
PR and Communications Manager, ANCA
M: +61 439 316 131
Sepideh.Zandieh@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide. ANCA CNC grinders are used for manufacturing.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

ANCA website: www.anca.com

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Facet Precision Tool — Key to Success

Jeremy Bunting leverages insights gained from growing up in a hugely successful cutting tool business to build a brand new specialist company – Facet Tools

Jeremy Bunting, Managing Director of Facet Precision Tool grew up in the cutting tool industry, getting a hands-on education from a young age and then using this experience to start his own business. From laying out a brand-new manufacturing center; to shaping and promoting Facet’s reputation; to training up a high performing team who are passionate about the craft of cutting tools – Jeremy has built the foundations for success.

Jeremy begins:

I started designing my first tools at age 14 in America as part of the family business, using manual grinding as well as conventional grinding to manufacture tools. After that I moved on to the applications side – getting exposure to feeds and speeds and eventually moved to Europe.  In Europe I worked for different tooling manufacturers, seeing different approaches to manufacturing and precision tooling.

I started Facet Precision Tools in 2015 primarily to service the aerospace and automotive sectors. Both these markets require special tools with distinct needs. At Facet we produce PCD, carbide cutting and coated carbide tools through distributors and direct to customers. Based in Germany we sell locally as well as to France, England and Spain. Through distributors we service Africa, Sweden, Turkey, Hungary, Austria, Italy and Mexico.

It’s challenging starting a new business. We had a market and products in mind and were in a unique position where we could decide, if these are our target markets, what machinery and equipment do we need? I considered my past experiences in the industry and how can I apply any learnings to the future. When we entered the market, I wanted to have high quality equipment, robust manufacturing processes and be producing market leading cutting tools.

Since opening we have been growing steadily, in fact last year we doubled our sales. As we expand we are looking at how we can attract more customers, consider if we need to add additional products and as many people in the industry experience – are always looking for good people.

Establishing grinding capabilities

After deciding on a shop floor blue print, we invested in a range of ANCA machines with two MX7 Linear’s, an FX7 and an EDGe as well as other equipment. We use the MX7s primarily for automotive tooling as they work well when grinding tools with larger diameters of 20, 25 and 32. We also run a lot of pocket grinding for PCD cutting tools on this model. The MX7 has a lot of horsepower that allows us to grind these tools in a very stable way. We use the FX for high volume carbide tooling. As an extremely rigid and thermally dynamic, stable machine I can rely on it to grind highly repeatable cutting tools.

On the MX7 we have an ANCA spindle speeder that allows us to achieve higher rpm. We worked with ANCA to adjust the software to be able to provide a better stable pocket and more accurate pockets in our grinding process.

On the EDGe we manufacture PCD tools. In the past couple years we have been developing PCD vein tools with our own blanks and cutting tool designs – working through and refining our processes. The EDGe has allowed us to have a high degree of accuracy when trying to grind a lot of the geometries. I found that as a process, erosion enabled the repeatability and the quality we were looking for. We also added a vision camera system on the EDGe, allowing for a quick inspection inside the machine, to get higher repeatability and better quality versus taking it out of the machine, and putting it back in.

And then there is ANCA’s 3D Simulator program. Up to 95% of the designs and problem solving are done on the simulator; testing the grinding process, reviewing and modifying before you go into a machine. It is our strongest tool to increase efficiency and reduce waste and that is a major help to our profitability. For example, carbide is extremely expensive where you can be paying from 400 euros for a 32mm standard rod.

The simulator also shows estimated grinding times which has been a great tool for us to reduce cycle times. Last time it took us, for example, 20 minutes to make this tool, but after considering a new idea or different approach we can reduce that time to 18, 17 or even 15 minutes all through experimenting in a simulated grinding environment.

We have touch probes on all the machines that allow us to easily change wheel packs, qualify the wheel and start moving quickly. It also allows us to remove human error and ensures a higher finished quality. To be able to dress and probe the wheel, picking back up where you left off without having to change the setup is very advantageous.

One of the main reasons we love the ANCA machines is because of the software. We have found it to be extremely flexible and at Facet we don’t use a lot of the standard ANCA programs and designs and instead do a lot of our work in profile editor, changing angles and profiles to meet the tool designs that we need. My Dad always said that ANCA was a software company that built a machine.

Part 2
Facet Precision Tool comments on why building a team of craftspeople is key to success and whether the electric car be the demise of the cutting tools

Jeremy Bunting, Managing Director of Facet Precision Tool grew up in the cutting tool industry, getting a hands-on education from a young age and then using this experience to start his own business. From laying out a brand-new manufacturing center; to shaping and promoting Facet’s reputation; to training up a high performing team who are passionate about the craft of cutting tools – Jeremy has built the foundations for success.

Specials are a relationship business – requiring communication and trust

As we build our company we want to be known for quality. From the start we have been trying to build our reputation for offering high quality tools rather than just entering a market and throwing anything out there and seeing what sticks. We are methodical in our approach to manufacturing certain tools or entering a marketplace or approaching certain things. Even if this means we are a bit slower and more tactful.

Just as important, is our responsiveness to the customer through deliveries and application support. These are the foundation of our company. We start by listening – what does the customer want to achieve, am I understanding their needs correctly? Then I consider how the product could be improved, can we make other recommendations. We turn that request into a tool design that is checked by the customer.

In aerospace, a common misunderstanding is the need for standard tools. Tools for aerospace require different lengths, diameters and applications. There is also a high requirement for accuracy, in Europe for example, we find aerospace have applications that need to be measured to a couple of microns and use a variety of methodology to make holes in different materials. It is a challenge making a product meet quality standards while working across a range of material applications.

Building a team of craftspeople

I think working in specialty tools excites an element of craftsmanship. Every day is different, and you can take pride in your work, was it correct, was it to print? That is why we look for a person who is flexible, shows an ability to learn, grow, and absorb information.

I train everybody in my plant like they’ve never seen a grinding machine before. We invest time to build their knowledge base to understanding the manufacturing and measuring equipment. Again, partially because we’re into specials where every tool design is different, we don’t have pre-written programs.

I think one of the best characteristics of a toolmaker is an attention to detail. Often people can become over invested in the productivity side – how many parts can I get through, how fast can I get them through the line. I train my team to be focused on the quality of the tool first and productivity second. And to meet these expectations of quality you have to have a high attention to detail.

Just as important is to develop your team to have a passion for grinding. The more passion someone has for the product, the more likely they are to stay. Teaching your employee how to make a better-quality tool feeds their creativity and teaches them it is ok to have your own approach and style. At Facet we have an open dialogue with our teams of why we do the things that we do.

Trends in the market – will the electric car be the demise of the cutting tools?

If I think about what I am seeing in the market I would say there is more competition in the automotive field than there is in the aerospace field, probably because aerospace requires more project work, more support, more testing, more engagement with the customer. Automotive expects high quality tools at very high tolerances, we have reamers that have tolerances of only a couple of microns. Another focus for this industry is price.

As the use of composites in aerospace has increased so has the demand for PCD or diamond coated tools. For example, the Dreamliner or A350 or Boeing Dreamliner uses a large amount of composites. These are extremely abrasive so if you use a carbide tool to grind composite materials, initially the tool works great but the wear curve is extremely high so after a 150 holes, the amount of wear is accelerated on that tool until it becomes blunt.

This changes the dynamic of the cutting, the heat, burr creation; causing problems for the manufacturer. Whereas if you use a qualified diamond or PCD tool, you may be able to make up to 1500 holes. For a customer that means higher productivity, fewer changeovers, less inventory and a higher degree of quality for a longer period of time.

There is speculation that combustion motors will disappear and as motors disappear then the need for a lot of the cutting tools disappears. This is bringing up questions on how much electric cars will replace all other means of transportation. Personally I think there are a lot of hurdles that have to be overcome and we will see other opportunities as the market changes. I think as far as aluminum and composite manufacturing is concerned we will see them trying to go lighter to make combustion engines more efficient.

I think there will always be a need for niche and special products and that means more special cutting tools. That’s one of the reasons why we were very comfortable moving into this industry. So as materials change – if it’s more glass, carbon composites or aluminum – we’re in a good position to move with the market and respond to those changes. I have established the foundations of Facet Precision Tools to be agile with design expertise, workforce skills and manufacturing capabilities. We can and do adapt and invest in the machinery or develop our knowledge so we can meet the markets’ changing needs rather than focusing on materials.


For further information, please contact:
Sepideh Zandieh
PR and Communications Manager, ANCA
M: +61 439 316 131
Sepideh.Zandieh@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

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Exact Metrology Provides Updates on PolyWorks Inspector™ and Hexagon Romer

Exact Metrology Free Training VideosExact Metrology, a comprehensive metrology service provider, recently published informational videos on PolyWorks Inspectorand Hexagon Romer Absolute Arm on the company’s YouTube channel at https://www.youtube.com/user/ExactMetrology/videos.

A new feature in the PolyWorks Inspector™ is multi-piece editing. Users can now make changes in one piece that can be propagated to other pieces. If a user has multiple pieces, they can make changes like creating, editing features, alignments, reporting items, etc.  Then, these changes can be transmitted to past and future pieces/templates, create custom propagations or just apply the changes to the current piece. After choosing the propagate option, the user sees the changes in the other pieces and/or templates including report(s) or report items.

Another update of PolyWorks Inspector™ pertains to augmented GD&T. Center point features can now be reported with more capabilities. These include circularity, flatness, perpendicularity, etc. Users can also see MIN/MAX deviations and can view the color arrow deviation tags.

An online tutorial shows how to make sure the Hexagon Romer Absolute Arm is still in calibration. First, the bar artifact needs to be placed correctly to scan it. The ideal location is centered with the main axis of the arm at a distance away where it will be just below the elbow when the arm is extended out. To secure the bar, use pre-drilled tapped holes. They accept simple machinist fixturing to hold it in place.  C-clamps can also be used to secure the bar to a rigid table. When doing a length checkout, only the 15 mm master probe should be used.  Next, the user needs to open RDS Data Collector. Used with Hexagon Romer Absolute Arm, the software allows the operator to check the accuracy of the arm and probes and calibrate/align the probes and scanner as necessary. To start probing, move the probe to the first position. The probe needs to be properly seated in the conical feature at each end of the bar. Following the prompts in RDS, move the probe to the end conical features and pull the trigger to record a point. Once ten positions have been recorded, RDS will display the results. The MIN/MAX values should be below the standard values for the type of arm being used.


Exact Metrology is ISO, AS9100 Certified as well as FFL and ITAR Registered.

Exact Metrology, with facilities in Cincinnati, Ohio, Moline, Illinois and Milwaukee, Wisconsin, plus affiliated offices throughout the country, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings.   The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

 

For more information, please contact:

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Local: 262-533-0800
www.exactmetrology.com
deans@exactmetrology.com

 

EXACT METROLOGY, INC.
Steve Young
11575 Goldcoast Drive
Cincinnati, OH 45249
Local: 513.831.6620
Toll Free: 866.722.2600
www.exactmetrology.com
stevey@exactmetrology.com

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Goss Magnapak Inserter Performance Improves 15% With Siemens Controls

Siemens “Solution Partner” Advanced Industrial Controls provides Goss Magnapak inserting system upgrade together with Enternet Control Systems (ECS) in seven weeks.

In the world of high-speed Newspaper production printing and inserting, the need to remain at peak performance is paramount.  Recently, a leading bindery and newspaper equipment and printing controller supplier, Enternet Control Systems (Glastonbury, Connecticut) was presented the challenge to retrofit a Goss Magnapak newspaper inserting system.  ECS serves many of the largest magazine, catalog, and newspaper printers in the country.

Magnapak inserter underwent a total retrofit on the control hardware and software, including Siemens electrical components, software and HMI.

Turning to its partner on this project, Advanced Industrial Controls (AIC), a St. Louis area Siemens-authorized Solution Partner who specializes in field service and machine retrofits in the printing industry, ECS conducted a joint situation analysis to determine the components and software needed.  It was decided that a complete electrical control and motion upgrade was required, necessitating the replacement of obsolete and tech-incompatible components, software and HMI.   

The obsolete OEM inserter controls on the machine were to be replaced with a new ECS eNews Model 3000 Controller for monitoring and control of the inserter, along with downstream tracking and stacker control.  Interface to the new controller over ProfiNet was required to allow multiple machine components to be interactively linked.  Interface to customer’s existing planning system was provided through the eNews system as well as connectivity to the customers other four (4) existing eNews systems to enable flexibility in production as well as comprehensive reporting. 

As the systems integrator and controls specialist on the project, AIC utilized the industry-proven Siemens Printing Solutions system architecture, which includes all the hardware platforms and software libraries for high usability and standardization.  Having this capability handy drastically reduced the system evaluation and field testing required, from the sensors to the drives, PLCs, motion controller, HMI and wireless data communications hardware, as well as software. 

Padraic Stapleton, project engineering manager from AIC, comments, “Using our experience retrofitting machines across many industries and our in-depth knowledge on the operations on the Magnapak, we first determined what functionality was needed for this machine.  This included high-speed motor synchronization, safety requirements, high-speed signal processing to and from the ECS eNews controller, an ability to recover smoothly from bus failures, elimination of obsolete components, simplified operator controls and the ability for the customer’s maintenance personnel to troubleshoot issues.  We then utilized our experience with the various Siemens product lines and chose the appropriate components and software to meet the requirements.” 

AIC provided all back panel and prewiring construction offsite to reduce install and startup time at the end user location.

Stapleton further noted that an aggressive project schedule was devised to fit the customer’s production requirements.  This schedule comprised pre-engineering and fabrication that were performed at the AIC facility, including testing.  This pre-onsite work allowed AIC to minimize the machine’s downtime and the actual installation was completed in seven days, as planned.  The customer was ready to go online in seven weeks, also per plan.  “This time frame exceeded the customer’s expectations and, overall, the project was completed on time, on budget and without any hiccups,” Stapleton mused. 

An ambitious goal was set for this retrofit, as the result of these component and software upsides. The target for completion of the entire project was only two months, with installation calculated at one week and going back online in seven weeks. 

Functionally, all hardware was powered up, configured and tested at AIC by their personnel, prior to beginning the install. AIC prewired all the hardware and also manufactured the back panels for the hardware, to further reduce install time onsite. At the customer’s location, all installation was indeed accomplished in one work week, performed by AIC technicians, so no other outside contractor costs were incurred, and plant personnel were freed to perform other tasks during the install time. 

All work was performed onsite by AIC technicians, requiring no outside contractors or customer plant personnel.

The startup was indeed completed in seven weeks, including all I/O checks, drive/motor tuning, testing of the entire Siemens motion control system plus training of the operations and maintenance personnel. Every station in the entire line on the Goss Magnapak was revamped, including the PLC enclosures, main drive cabinets, hoppers, releases, master and slave HMI, with wireless Scalance data transmitters provided for flexibility and mobility in the system.

Following restart of the line and over a tracked period of time in production, the end user’s plant has reported an ongoing net production increase of 15%, compared to the line performance before this upgrade and retrofit of the motion control system. Benefits to the end user included the elimination of obsolete components, a substantial increase in reliability with the new Siemens hardware, increased diagnostic capability resulting from the built-in data tracking tools and connectivity on the Sinamics drive system, a decrease in the complexity of the machine functions due to the incorporation of integrated safety functions in the new drives and most notably increased usability and flexible staging possibilities of the eNews controller onboard. At the most basic level, the distributed I/O system is highly scalable and connects seamlessly to the central controller over Profinet.  A plug-and-play scenario is provided, making alterations on-the-fly more practical, faster and requiring less training time for the operators. 

Plant reports a net production increase of 15%, compared to machine performance before the upgrade.

From the safety side, all e-stops, pushbuttons and guard switches are connected to the safety PLC through integrated safety I/O, with Siemens ProfiSafe onboard to control the STO (Safe Torque Off) function to all the drives in the system. 

Device replacement was simplified, as the new devices can be detected and configured via the communication network to allow the replacement of modules without the need for any reconfiguration.  The system automatically addresses and names the replacement modules, saving substantial setup time per station. 

Pre-tested printing solutions from Siemens provide faster startup and operator interface. Increased diagnostics with built-in tools on the controller improve machine troubleshooting and resolution of any performance issues.

With integrally redundant Sinamics drive communication, in the event of one hopper drive or Profinet cable failure, all other hoppers remain operational and the drive can be disabled from the HMI without rewiring. 

Following restart of the line and over a tracked period of time in production, the end user’s plant has reported an ongoing net production increase of 15%, compared to the line performance before this upgrade and retrofit of the motion control system.  Benefits to the end user included:

  • elimination of obsolete components
  • substantial increase in reliability with the new Siemens hardware
  • increased diagnostic capability resulting from the built-in data tracking tools and connectivity on the Sinamics drive system
  • decrease in the complexity of the machine functions due to the incorporation of integrated safety functions in the new drives
  • increased usability and flexible staging possibilities of the eNews controller onboard. 

At the most basic level, the distributed I/O system is now highly scalable and connects seamlessly to the central controller over Profinet.  A plug-and-play scenario is provided, making alterations on-the-fly more practical, faster and requiring less training time for the operators, according to the end user. 

Stapleton concludes, “The Siemens drives were chosen due to multiple reasons, including integrated safety functionality, built-in high speed inputs and outputs that were required for specific machine functions, proven hardware reliability, simplistic overall hardware architecture, proven motion synchronization functionality and the ability to have the drive configuration parameters integrated into one software programming package.” 


AIC is a full-service integrator of electrical and automation systems, working the full suite of Siemens motion control components, robotic, SCADA, networking, power distribution, bar code, RFID and vision systems.  The company further provides turnkey control panel fabrication, field service and parts inventory for customers. 

With over 30 years in the industry, ECS offers its customers a wide range of inline bindery, newspaper, wrapper, mailtube and co-mail control systems for selective pocket feeding and tracking, multi-station inkjet addressing plus integrated camera technology for signature recognition, read and print capability, IMB and bar code verification. 

For more information on this story, please contact: 

Jason Tretter, President
Advanced Industrial Controls
1000 Eleven South
Columbia, IL 62236
618-977-4576
www.advancedindustrialcontrols.com

 OR

Dave Carlos, Sales & Marketing Manager
Enternet Control Systems
21 Sequin Drive
Glastonbury, CT 06033
877-477-1325
www.ecsbindery.com

OR

John Meyer 
Siemens Industry, Inc. 
Digital Industries — General Motion Control
380 Kent Avenue 
Elk Grove Village, IL 60007
Phone:  847-640-1595
www.usa.siemens.com/motioncontrol

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