Go with the flow: Industry Trends & Analysis

GPI also knew that it needed a way to ensure there weren’t any machining issues for the FMS and to monitor and validate machine kinematics in real time before cutting any metal. “That way there’s no chance of harming an operator or wrecking a $30,000 spindle and being down for a week while it’s being replaced,” Alcala added.

GPI determined that the safety net that should sit beneath it all is VERICUT machine simulation and optimization software from CGTech, Irvine, Calif. Programmer Matt White has used VERICUT for nearly 10 years and said he was confident that there was no need to examine or test any other verification software packages, adding that the software prevents mistakes—however rare.

GPI installed a flexible manufacturing system to compete with offshore suppliers and revitalize the shop floor.

“Even programmers mess up sometimes,” he said. “When they do, VERICUT is there to prevent catastrophic damage to expensive equipment. It saves us in so many ways: money for repairs, machine availability, operator injury, tool damage and, ultimately, time. That’s the one thing we can’t get back.”

Just as important is program accuracy, White added. By using the software’s AUTO-DIFF function, which compares the part’s CAD model to the toolpaths used to machine it, errors such as gouging and out-of-tolerance conditions are detected in advance, avoiding costly rework. In addition, because toolpaths are graphically displayed, it’s easy for a programmer to minimize idle time and reduce inefficient code.

GPI split the initial project into two phases. The first phase involved installing two machines. The second pair will be delivered in early 2016. “We opted to go with two machines at first,” Alcala said. “This gives us a chance to figure out our processes and make sure everything is bulletproof before introducing the next set of machines. By March, we expect to have all of our cast iron running in-house.”

Implementing FMS is not simply a matter of installing the machines. GPI has been on a steep hill of process improvement, such as switching side-lock toolholders to balanced shrink-fit holders and working with a nearby tooling house to design and build a lean, SMED-style (single-minute exchange of die) hydraulic fixturing system. That system provides quick changeover between jobs, rigid workpiece clamping and repeatability.

VERICUT can also simulate probing cycles. Implementing this feature is another item on GPI’s process-improvement checklist, but Alcala said it’s nice to have. “Our first priority is to avoid causing harm to our employees. Anytime you must stick your head in the machine to prove out a program, it’s very dangerous. I’ve seen where a retention knob breaks off in-process and the tool is bouncing around inside the machine. Imagine what would happen if one of my employees were struck by that.”