New machines with new technology often boost productivity, but Jergens Inc. Production Supervisor Jason Bateman was looking for something more. Boosting part production for the Kwik-Lok®, quick release, Pin Line started with new equipment but Bateman credits the smooth, production ramp-up to little-used, little-known parametric programming.
When deciding to tackle a production process at a company, how each facility approaches it will vary, but all are trying to get the same result: saving time and money while increasing quality and productivity. For Cleveland, Ohio-based Jergens, having the industry knowledge Bateman brought when he joined the company – a little less than four years ago – meant they had a fresh set of eyes on a long-standing process.
“We basically did a wholesale change in the way we approached manufacturing these parts,” Bateman says. “Previously, we were taking and creating a program for every part, which was a pretty substantial process – costing time for programming, set-up, and prove-out. Switching to parametric programming and the Marubeni Citizen-Cincom A20VII machines delivered more advantages than we expected.”
It sounds simple, but the project entailed more steps at the start and additional changes prior to the first run of the machine. Once done, however, it’s turning heads on the shop floor with how this process can be applied to other machines and cells at the company.
Jason Bateman’s take on parametric programming
What’s interesting, conceptually, is parametric programing has been around since the 1970s.
It was born from the fact that earlier controls did not have the capacity for long lines of code; they only had so many feet of memory. So people developed this second language, initially called Fanuc Macro A and the modern day version, Macro B, which we are using on this project, and they have gone in and gotten creative to write logic that does iterative looping, math, calculations, storing stuff, and accessing records as in earlier computer days. That technology – as advanced as everything is today – that hasn’t changed, and many don’t know it exists. Many Swiss shops haven’t heard of it.
In previous positions, such as when I worked for a company that did consulting to job shops and facilities that had older, but high-end equipment with very small memory capacity, we used Macro B and logic all day long to facilitate this complex stuff.
It’s not unusual for companies not to use everything that’s available in the toolbox. Some of the companies I consulted for didn’t jump on board with available CAM programming until well into the 1990s. With the Marubeni Citizen-Cincom A20s and the parametric programming, we are transitioning as well.
Making the change
“Our objective to this project was how we can reduce setup time, increase throughput, and on what machines this will work best,” Bateman says. “We have some rotary transfer machines and we can use them, even writing parametric programming for them, but our volume isn’t as large as what you would typically see on those types of machines. With a 12- and 16-station machine, setup was taking between 4 and 8 hours for an established process. A new process required days. With that approach, an operator is in pretty deep and committed to running the job on that machine.”
In addition to the transfer machines, Jergens machinists also used Marubeni Citizen-Cincom L25 Swiss machines for the parts. However, similar to the other platforms, each one required an individual program – adding to the time and cost.
That is when Bateman started to look hard at the A-line and discussed the benefits with Concentric Corp., the machine tool distributor Jergens has used for more than two decades. Once settled on which machines they would add to their arsenal, Bateman talked with Dane Hockman, Concentric’s sales representative, about parametric programming.
Parametric programming comes in several versions depending on the machine control. Programming can include computer-related features such as variables, logic statements, and looping. Most versions of parametric programming have extensive CNC-related features, allowing users to access more from the CNC control within a CNC program.
“It was a combined effort on writing the parametric programming for the machine. I provided the concept to Concentric and they came back with their idea as a starting point. They had never gone this route on any of their machine installs, so this was somewhat of a new area for them as well,” Bateman says. “So, we brought the programming in-house, and Dane and I worked for about 3 to 4 weeks beating it up, changing the logic, tweaking this and that. By the first week of January we had it all straightened out and it was a go.”
Once ready to operate, the parametric programming delivered more than anticipated.
With the new logic and code, the programming is loaded into the machine, which can automatically change from a length, to a length, to a length without operator intervention. This approach expedites manufacturing and improves quality while addressing the challenge many companies face – a lack of high skill sets – since parametric programming is eliminating the need for heavy operator intervention.
“We brought the machines in and from the first day, we started with a dispatch list of parts we were going to run for the day. Now, the machines still stay on for 20 hours a day, 5 to 6 days a weeks with maybe 15 to 20 minutes here and there for some cleanout and maintenance on the guide bushings, sub-spindles, etc.,” Bateman notes. “With this approach, it’s pretty wild that due to the efficiencies in the A-20 process we are competitive against the transfer machines’ cycle times.”
One of the key reasons is the elimination of changeover.
Better workers
Another soft benefit that came with switching to parametric programming is better workers. As Bateman acknowledges, a lack of skilled workers is something that everyone struggles with – especially when it comes to running Swiss equipment. So, they have to be very careful with letting a new employee start on expensive machines.
Bateman says that once he explains what’s going on – the flow, the process – employees can attach to it and find out where they fit in the mix of what needs done.
Because of this concept, Jergens has the ability to introduce employees to the machines in small doses that promote building confidence in a series of tasks, then they can be safely graduated to the next level. It starts with operations/checking parts, then entering dispatch lists, and finally tool changes and maintenance.
“Now we see the levels develop, and some employees across the spectrum fit the gaps and feel confident and productive, and they aren’t in danger of crashing a machine,” Bateman says. “With the long-term employees, those full of experience, initially they want to challenge the changes. However, once we get them on board to try the new way, and they go back to their old cell, almost instantaneously they are asking when we will upgrade their cell to work with parametric programming. Once they know and understand it, it’s a no-brainer and everyone benefits.”
One program, multiple parts
Jergens employees use the A20s to produce two-ball or four-ball parts with different handle configurations for the Kwik-Lok Lifting Pin line. The operator loads the material into the bar feeder and can lock it in on that diameter for a day or a week. No matter what the job order calls for, with the programming in place on the machines, the only thing the operator needs to do is load the new list of lengths.
Bateman notes there were additional benefits that came from this approach not originally anticipated.
Product line expansion
The primary business is the single-acting, two-ball type. However, with the logic in place, Jergens employees can now accommodate single-acting 4-ball, and a detent pin, which does not have the through-hole on the end but does have the cross-hole.
“We can do four to five variances now, and that was not our original intent, but it’s worked well. This has worked so well that we recognized the impact it has on our scheduling system and tooling use,” Bateman states. “We use an ERP system which is not very friendly when it comes to grouping things together; it wants to do things just in time. It keeps shuffling the deck to align the stars, and if you don’t run it there, it’s not happy. But what we have found is we can run those small orders in diameter groups, such as a wheel of diameters, and in a month or less have cleared that wheel and are ready to start at the beginning again.”
Better material management
Throughput is through the roof, setup numbers are off the charts, since that step is nearly eliminated, and changeover is close to obsolete. The consistency is enabling Jergens to maximize the bar stock loaded into the machine. With increased knowledge of remaining stock in the bar feeder, remnants can often be used for smaller-sized parts since the program can accurately track what’s left.
Currently, they are seeing a planned versus actual use of machines running between 107% and 135%. Basically, the 10 minutes that may have been planned for each job for setup is not needed, and that gets divided across 30 jobs, which results in nothing per job. Any scheduled time for changeover is out of the equation too.
Tool life management
“The other big benefit we have seen with this is the tools used for the job. We have designed specific hole making tools for the cross hole process, which we purchase in bulk and watch via a tool life monitoring module Dane and I built,” Bateman explains. “We wrote it together and have been massaging it along the way because this is not available in the format we need off the shelf. It clicks off each time a tool is used, implementing the logic we added that says ‘When the tools hits X number of uses, follow the next step.’ So, we now have a very predictable and traceable tool life, where before it was a challenge.”
Bringing in the parametric programming approach has been a huge education on tool life and tool wear when producing these parts, with Bateman admitting that they were really in the dark previously. Now everything they do is monitored and measured and it’s making significant impacts; the intangible results that came out of these changes are some of the largest.
“We have really crunched tool costs. Those have gone down 40% to 60% in some cases. We have the machines broken out with one machine doing up to 3/16" to 5/16" and the other does 8mm to 1/2". Now the one doing the 3/16" to 5/16", we will have insert life doing this turning in a few spots, as well as under the handle and the inserts do 14,000 to 15,000 pieces,” Bateman explains. “Now, if you look at the tool crib reports they go by employee and what they are pulling and where they are working. Previously, we would see crazy stuff, such as people pulling three inserts a day.”
Because of the system’s tracking of tool use, inserts last 4-to-5 months versus the previous record high of 90 in a single month – a savings of roughly $4,000 per month.
Looking down the road
When a new project is started – especially one that will change the status quo – it’s often met with resistance and hesitation from employees who will have to embrace the new methods. Bateman acknowledges that some of the long-time employees were wary at the start, but now they are asking when they will get the logic programming to make their production cell more efficient, while managers want to know if even more can be added with parametric programming to help with analysis.
Currently, Bateman and Hockman are in the process of writing the logic for the Marubeni Citizen-Cincom L25 and L20 platforms to do the same process but on the smaller segment of their business, which is anything above 3-3/4" and in all the available diameters. Additionally, they have started some experiments of plugging this idea into their quick-reaction cells of two Haas mini-lathes. In this scenario, the operator plugs in the length and the machine comes over, parks itself, pulls the bar out to the stop, and it’s a go to make the length needed without specific stops, programs, and more.
This latest process started when it became obvious that production issues would arise because of the need for a program for every part produced in the Kwik-Lok Pin Line. Now that Bateman has moved them to one program that does all the sizes on the A20s, the focus can move to other areas for further improvements.
“We have washed all the variables out of the mix, and from that standpoint, quality and production have definitely improved. With the parts we are making, we always have the same edge break on the end, the same edge break on the transition, and the same edge break at the top. The little things that make things go have been all smoothed with this programming, and the production of any required length is smooth sailing.
“We have spent a lot of time trying to implement these improvements. It’s been a neat adventure with dramatic changes,” Bateman concludes.
Jergens Inc.
www.jergensinc.com
Marubeni Citizen-Cincom Inc.
www.marucit.com
Concentric Corp.
www.concentriccorporation.com
Elizabeth Engler Modic is the editor of TMD magazine. She can be reached at 330.393.2064 or emodic@gie.net.
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