FILTRATION: A KEY TO SUCCESS

Making precision tools for surgeons is what has enabled NG Instruments to achieve consistent growth over the years. "The demands of this market for precision drills, taps and reamers is quite different than your typical contract cutting tool manufacturer," states Tony Nicholas, president and co-founder.

The range of products NG Instruments manufactures can include drills for a bone screw, joint replacement tools for hips, knees and shoulders, and precision spinal tools with built-in stop control where OAL and length to stops must be held to a close 0.005" tolerance.

INVESTING IN TECHNOLOGY

In the last several years, NG Instruments has invested extensively in new machine technology. Every machine tool in the shop is less than five years old. The majority of their medical instruments are manufactured utilizing five ANCA TX7s and four ANCA RX7s.

All the tools manufactured on these machines are stainless steel with hardnesses ranging from 38Rc to 55Rc, depending on the grade of steel required.

"There are typically 16 to 24 operations required to build a single tool from bar stock," Nicholas says, "and cleanliness is obviously a critical specification." Initially, NG Instruments deployed a centrifuge system to filter the oil coolant used on their tool cutter/grinders, but the filtration system accompanying the purchase of their first ANCA in 2006 was a Transor Filter. "We quickly discovered that filtration could add a whole new dimension to our production," Nicholas continues. "We were amazed from the outset."

A SIGNIFICANT DIFFERENCE

Tony Nicholas was quick to point out that the Transor impacted virtually all aspects of NG's machining operations.

"Our first reaction was that the coolant was so much cleaner than we had been seeing with the centrifuge. You could physically see the difference. It still looks as brand new as the day we first poured it out of the barrel." He goes on to explain that the centrifuge required daily maintenance by NG operators. They had to physically shut off the machine so the tanks could be cleaned. "They were up to their elbows in oil and sludge," Nicholas states.

Now with Transor's automatic backflushing, the filter elements are cleaned without any machine downtime. Nicholas points out that with the Transor, every couple of weeks they simply empty out the system's sludge bags, making this process quicker and cleaner with no machine downtime. "My operators are a lot happier as well," Nicholas says.

MAXIMIZING ALL ASPECTS

"Without debris building up on the wheel," Nicholas explains, "we have been able to increase feedrates. And, with less build-up on our CBN grinding wheels, we have been getting about 25% longer wheel life. It makes a huge impact when you are not re-grinding the tools own scrap." NG's customers' high expectations for cleanliness of the parts are met dramatically by 1µ filtered oil. Nicholas also attributes the improved surface finish to Transor Filtration. "While it is difficult to actually measure down inside the flutes of some of our micro drills, there is a visible difference as we remove the parts from the machines." Nicholas then doubles back to mention that the capital investment that NG Instruments has made over the last several years has been considerable.

In addition to the simplified maintenance previously addressed, he points directly to the 1µm filtered oil as an added benefit to protecting his investment.

"After three years, we just have not experienced the wear and tear on the ANCA machines with the Transor system, compare to what is typically associated with tool grinding, especially stainless steel. Normally, grinding machines look pretty bad after a year or so, but this machine still looks brand new."

THE FUTURE

Nicholas feels he has a real partnership with both ANCA and Transor in moving his business forward. He mentions that he is currently working with Transor to install one of their new magnetic separators. "I think that will really improve the ability of what the Transor can do for us and take it to another level," Nicholas concludes.