Great article, why does it take so much to convince companies when the data is so clear. Some companies will not even participate in a free "walk thru" because they fear you will find a non-compliance...

I am having a problem with spindle assembly vibrations on a vertical machining centre. The spindle center to the column box guideways is 500 mm. The box guideway is 90 mm wide with turcite wedges. In the Y direction, i.e. in the Y-Z plane, vibration is 0.2 mm/sec, but on the X-Z plane it is 3.2 mm at 8000 rpm of the BT 40 taper spindle. Can you help to reduce the vibration on X-Z plane? What is the value of vibration allowed in such cases?

I heard a story on BP and how it has damaged a good many suppliers by ordering clean up supplies and not taking delivery, and today read a story about the rebound in manufacturing and the shortage of technical workers. I think this article neatly and succinctly connects these two seemingly unrelated news items to your central theme: manufacturing is on the brink of a significant change and only those manufacturers that change for the better will survive. Small shops have to be careful not to rely too heavily on one customer and manufacturers have to recognize that the vast pool of manufacturing talent no longer exists. As manufacturing has advanced the skills required to work in manufacturing have exponentially increased and many smaller firms will face tight competition in landing the best workers. Excellent article Mike

Hi David,

Both volumes of the Navy Steelworker manual are available online. I looked into your claim and so far it seems unsubstantiated by the data. On the other hand, it seems more plausible to me that the article is excerpted from Boljanovics own book, as claimed.

Would you be referring to another book?

Congratulations on receiving your <a href=http://www.iso-9001-checklist.co.uk>ISO 9001 Certification</a>

I have 2 questions please: (1) Could the true hole technology make the same cutting quality of the holes that laser cutting technology make? (2) Is the cost of the plasma cutting machine with true hole technology less or more than the plasma machine without?

Jim Colt responds:
On your first question, can True Hole technology make the same cutting quality of the holes that laser cutting technology makes? This question is a little tough to answer. The True Hole technology is a plasma, not a laser . . . so expect some features of the cut to be better than a laser cut hole in plate, and expect some features to not be as good as laser. Also, not all lasers are equal, and not all motion control devices are equal . . . so True Hole mounted on a large, heavy gantry cutting machine may produce some differences in hole tolerances as compared to the same process mounted on a small, lightweight precision cutting machine . . . similar analogies can take place with laser/machine applications.

In a nutshell:
1. Hole roundness. Assuming good motion control on both laser and plasma machines . . . the top of a True Hole hole and a Laser hole should be dimensionally similar and perfectly round. In most cases the bottom of a laser hole will be quite round as well, with a few small anomalies that are often caused by top surface irregularities that may affect the beam. The True Hole plasma hole bottom will have similar, but slightly more pronounced irregularities on the bottom of the hole, however the process is designed to bias any anomalies to the outside of the hole, therefore maintaining the top to bottom hole dimensions so secondary hole cleanup is unnecessary for bolt insertion.

2. Hole taper. Both processes produce a slight amount of hole taper. The True Hole hole will have slightly more taper as compared to most lasers . . . however normal oversizing of holes for bolt clearance is usually adequate to ensure that the bottom dimension of the hole is within specifications. On a 1/2 in diameter hole in 1/2 in thick carbon steel plate . . . expect the bottom of a hole cut with a conventional plasma to be approximately .060 in to .100 in smaller than the top, with True Hole, expect the bottom of this same hole to be .010 in to .020 in smaller than the top, and with most C02 laser processes expect the bottom to be .005 in to .010 in smaller than the top. These numbers can vary from machine to machine, and after wear on plasma and laser consumable parts . . . but this is a good comparison of the process capabilities.

3. Hole edge roughness, metallurgy. Plasma usually produces the smoothest inside edge quality on a hole in carbon steel, and there is minimal hardening (although this varies depending on the grade of steel) as the True Hole process uses oxygen as the plasma gas as well as oxygen as the shield gas ?? this gas combination effectively keeps the nitrogen content in ambient air away from the cut edge, minimizing the nitride hardening of the edge. Initial metallurgy stress tests performed on True Hole holes shows promising results, and may allow plasma cut holes to be incorporated into primary bridge structural components, an area previously reserved for drilled or punched holes. Most Laser cut holes in plate have high surface roughness, and are often not allowed for this type of application.

4. Cut speed. Plasma wins hands down with the ability to pierce 1 in plate in less than a second, and cut speeds that are 2 times to 4 times that of laser cut holes on plate thicknesses above 1/4 in.

On your second question, is the cost of the plasma cutting machine with True Hole technology less or more than a plasma machine without? The True Hole process utilizes newer technology in the Plasma power supply, the CNC control, The torch height control system, as well as the CAM nesting software. These are all of the same components that are required on any high definition class mechanized plasma cutting system. The cost of a new system with True Hole technology is essentially the same as the cost of a new system with high definition plasma cutting technology.

Thanks again for your questions. Jim

Great article,even better advice. When I need help with wiring in my office I call the <a href="http://www.springelectrician.net">Spring branch electrician</a> at MisterSparky-Houston for help.

We should bring all manufacturing back home and not over seas. Everything made over seas isnt made to last and most products are built like crap and are toxic. You can teach anyone to run a CNC machine, it doesnt take that long. This would create a lot of jobs if they arent given to illeagals and give back pride to the american worker. Also more things sold here should say MADE IN AMERICA with american parts and labor. No Im not a part of any union , just a person tired of buying junk.

This nation became a world leader due to the industrial strength it &quot;had&quot;. I agree with this article that we need to focus on a way to generate new manufacturing industries. It will put people back to work and promote resourcefulness.

Industry is its own worst enemy!
It is easy but also very short sighted to lay-off workers to meet a certain quota.
It would be much smarter and more cost effective in the long run to pick out reliable employees for upgrading their skills or re-train them for a different skill.
Send them to school and you end up with employees which met your exact needs.

HOW TO SLIT BURR FREE MATERIAL IN CRCA COIL LESS THAN 1 MM

NICE ARTICLES. THANKS. LOOKING FORWARD TO MORE SUCH ARTICLES.

Yes. The details about manufacturing economics were good and very helpful, too. Thank you. Could you please throw some more light on the principles and uses of economic analysis in manufacturing economics? Editor replies: The large scope of manufacturing economics exceeds the area of discussion here. There are entire college courses devoted to this subject. For example, reference the Purdue University curriculum at https://engineering.purdue.edu/ProEd/courses/credit_courses?course=IE59000&amp;semyr=SP2010&amp;crn=41724 for more information.

DoE is vital in quality improvement. Its the active side of SPC and one of the primary tools for Six Sigma DMAIC projects. If you want more information on how it might be used in Six Sigma or SPC, please visit me at http://www.woodsidequality.com.

HI:
You are right. The Buick #31 plant had a "BIG" sign on the front of it for years (when I started in 1955 to 198?) that said "When better automobiles are built Buick will build them" Later around 1984 they started building engines that may not last for 50,000 miles but they considered the cost of repair of the ones they had to pay for (not all the failures).

Other countries get the same new profitable drugs for much less, why should we subsidize Canadians, Germans et al. With new price controls the cost of these drugs will just have to increase elsewhere. It is illogical to think that a private, for profit bureaucracy is somehow looking out for my best interest while a government one is not. Perhaps the editors should find some actual news to publish as opposed to some tired, year old Fox News scare tactic misinformation. Editor: Thank you for this feedback. Id be interested in revisiting your thoughts in 18 months. Then well see if this was accurate or not.

Excellent!!!

The Millau Viaduct is another great civil engineering feat! As a consulting engineer in Oakland,CA and San Francisco, CA, I can really appreciate the work it takes to get this project done. http://www.UrbanDesignCE.com

This site was good i found out a lot about my dads work!!!

I have not been a manager for this company for a year now. The fact that they have just released this speaks volumes for the type of sloppy operation they run. If you have NDT work, avoid them.

Note from the Editor: FYI Steve - this story was originally published in August 2009 . . . almost a year ago.