Maximizing global competitiveness: Turning Performance

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END USER: Alpha Machining and Grinding Inc., (704) 871-2183, www.alphamachiningandgrinding.com. CHALLENGE: Achieve cost savings through multiple process improvements. SOLUTION: Magnetic workholding and variable-index, variable-helix endmills. SOLUTION PROVIDERS: Alpha Workholding Solutions, (877) 217-6900, www.alphaworkholding.com; CGC Tools Inc., (866) 888-9600, www.cgctool.com; Turning Concepts, (704) 849-9209, www.turningconcepts.com

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R.P. Machine Enterprises Inc., Statesville, N.C., markets reconditioned gear production machines and provides technical services, including CNC retro- fitting, custom gear cutting and general machining. The company’s Alpha Group consists of Alpha Machining and Grinding Inc. (AMG), which performs precision grinding, machining and sawing, and Alpha Workholding Solutions (AWS), which designs, manufactures and sells permanent workholders, permanent electromagnetic workholders and magnetic lifting devices.

AMG produces several lines of midsize to large Blanchard-ground and machined steel plates. One line, machined from mild steel, includes versions from ½” to 1″ thick, 24″ to 72″ long and 24″ wide. AMG mills pockets, slots and the plate perimeters, and drills holes in the plates. Annual plate production volume is in the thousands.

Courtesy of Alpha Machining and Grinding

Alpha Machining and Grinding applies Gorilla Mill endmills along with A-Pod permanent electromagnetic workholding from Alpha Workholding Solutions to cut costs and improve productivity when machining steel plates.

To reduce costs and improve productivity, AMG addressed every aspect of the production process. “We have set up a better mousetrap than most folks,” said Marty Murawski, AMG general manager.

One effort targeted reduction of setup and clamping time when milling. The shop began using the A-Pod milling magnet system from AWS to boost productivity and cut costs by saving the time and expense of designing, building and changing fixtures for different-size plates.