Shop wrangles runout challenge: General Industry Coverage

In their 26 years, Homeyer Precision Manufacturing has taken on some of the most demanding industries and jobs. Perhaps the most precise yet is among today’s production lineup at the company’s 63,000 sq. ft., Marthasville, Mo., shop—bipolar, aluminum-based forceps used by neurosurgeons performing brain surgeries.

The forceps must meet exacting standards, and the machining setup had to maintain consistent precision through production runs in the thousands.

As the product gained popularity, demand from the customer grew, and so did the strain on Homeyer’s production. The setup at the time required increased monitoring after about the first 1,800 parts were produced. Because of runout, the endmill would lose its integrity and produce junk parts from part 2,200 to part 2,400, which required frequent tool changes by the operator and hampered productivity.

This wasn’t sustainable. The customer’s previous manufacturing process couldn’t keep up with demand, driving them to switch to Homeyer in the first place, and the shop wasn’t about to fall victim to a similar move.

Forceps shown, from left to right, in raw form to finished final product. All images courtesy BIG Kaiser.
Chart shows tool life compared to runout.

Mega New Baby Chucks from BIG Kaiser​. Click here for a video showing the chucks in action.

The tool holder in the magazine.