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SEPTEMBER 2008 / VOLUME 60 / ISSUE 9

The DMC 635 V ECO provides 3-axis vertical with 3-D simulation. Rightsizing Machine Tools By George Weimer Experts weigh in on how to buy smart—for today and tomorrow.

ow do you decide which is some advice from the machine “The best way to do this is to production equipment tool about how to buy literally list them on paper and Hto buy? How can you feel the machinery you need. It might check them off, one by one. An- confident that you are investing be called rightsizing. other thing that can help is to find in the optimal machine tools for “There is a long list of features a dealer or builder your shop’s needs? that any buyer must take into ac- who has machines on display and In decades past, before CNC can run sample parts on those and 5-axis and numerous other machines.” advanced technologies, purchas- Don’t be timid These days, many machine tool ing machine tools was relatively when discussing builders are out “econ- simple: You needed a lathe for cer- omy” machines. These produc- tain-sized parts and a milling ma- new technologies tion pieces of equipment are what chine for other jobs. with builders and one might call no-frills machine By contrast, a center tools. They don’t have all the bells today can produce more parts— suppliers. and whistles, but they offer an ad- of much higher quality—than an vanced technology package with entire shop could 30 years ago. count to ensure the machine that fewer features at, appropriately, Consequently, purchasing pro- is purchased meets present needs less cost. As some experts noted, it duction machinery these days is and foreseeable future needs,” ad- may be more economical for some complicated. Guesstimating and vised Kurt Zierhut, director of customers to consider adding fea- intuiting are out; economic and electrical , Haas Au- tures to new machines from other engineering analyses are in. Here tomation Inc., Oxnard, Calif. vendors besides the OEMs. Rightsizing Machine Tools (continued) Spread Sheets and Lists mum cutting feed rate, machine accu- “Most customers today use some kind racy, cut quality and chip removal. Again, of a spreadsheet approach that takes into with this complicated list, it may be eas- consideration details like travel,” said iest to actually run a sample set of parts Gisbert Ledvon, GF AgieCharmilles’ on machines where they are available by business development manager. Over- the dealer.” all, his advice is “buy a little bigger than Shops need to take a close look at these you need [because] spreadsheets some- machines and an even closer look at the times miss details.” CNC in general. You may find that there When considering new production are features available today in the CNC equipment, Ledvon suggested: “to look that you might want in the future. at the variety of parts you make or will “Certainly you will need to look at [make]. Pick the parts that offer the justifying the machine,” said Ledvon. most problems, and then discuss these One major measure of justification for and your concerns with the OEMs. machine tool purchases is productiv- Have them recommend solutions.” They ity improvement, said George Yamane, should show various machinery options, marketing manager for Mazak Corp., he added. Florence, Ky. “How much will you gain Much of this is straightforward, added in terms of productivity? That’s the best Zierhut. Consider machine size. “Does way to begin an analysis of new machine the part really fit inside of it? Con- tool issues. It’s not just price. If you only sider spindle power, spindle speed, tool look at price, then you are not investing changer speed, number of tools, maxi- for the future.”

The Haas Mini Mill 2, with extended travels of 508mmx405mmx356mm for the X, Y and Z axes, respectively, has a 40-taper spindle capable of spinning up to 6,000 rpm. Rightsizing Machine Tools (continued) Consider also your expectations in each element of capability. We need to terms of automation in your shop, said ask them, ‘What will you be doing in 5 Ledvon. “How easy will it be to auto- years, in 10 years?’ ” mate the equipment?” He recalled one Hyatt and others believe that the case where the introduction of automa- partnership between builders and users tion meant that the operator’s access was should be based upon long-term mu- compromised. It was, he added, a “disaster.” In addition, a workforce’s level Machine tools today can be as of and sophistication technically sophisticated as is an important consideration. Look at the equipment’s ease of advanced medical equipment— use and evaluate whether your or rocket science. operators are sufficiently sophis- ticated to handle it. tual trust. The OEMs need to always Partnerships in Production ask what the customers want to sup- Some machine tool builders suggest port. They do not want to overcompli- a partnership between the builders and cate the machines. “So we need to look their customers. “You need to under- at their business plan and take into con- stand the customer’s business model,” sideration that there are so many more explained Gregory Hyatt, chief techni- options now, which means a more criti- cal officer for the Machining Technol- cal review is required,” Hyatt added. In ogy Laboratory at Mori Seiki USA Inc., showing the OEM its business model, a Rolling Meadows, Ill. “We need to be shop allows the OEM to help strategize able to look at their own plans strategi- and consider the fact that “there may not cally. We need to understand with them be only one solution” when it comes to

The GF AgieCharmilles CUT 20 features a Windows XP-based control for easy setup and programming displays. machine tool evaluation, he said. “Is the OEM a stable company? How While Hyatt noted that “there’s too many machine tools do they have out much variability for a check list,” he does there? Talk to other endusers of their suggest that shops consider two major equipment.” areas of “future enhancement” for ma- If a shop is in the market for spe- chine tools. The first is software enhance- cialized machinery, it is dealing with a ment. Software is continuously evolving, narrow equipment niche, Ledvon said. and a shop should make sure its machine ”Your vendor needs to be able to pro- tool investments are capable of adapting vide technology options.” Discuss with to these changes. them the issue of what you really need A second area of enhancement is to stay competitive. in materials. “In aerospace, for example, the materials move Shop Around from aluminum to more titanium Sometimes it may be advisable to to composites over time,” Hyatt said. look at suppliers other than machine “You have to decide, do you want to tool OEMs for certain kinds of accesso- machine just one or two or all? Nobody ries and measuring equipment. Ledvon wants to buy a machine that’s obsolete pointed out that encoder manufacturers in a year or two.” can supply excellent equipment for ma- Another area of high importance in chine tools that might be less expensive deciding upon new production equip- than that provided by the OEM. ment is the OEM’s local service. “Be- “Most manufacturers have a long list sides looking at machine tools, look at of options,” said Haas’s Zierhut. “Don’t their service networks and their inven- get sucked into buying things you will tories,” Ledvon added. “Know how they never need, but certainly get those can help in terms of applications support. things you reasonably know you could Know what they charge.” use in the several years’ lifetime of a Further financial investigation of the machine. OEM is important, continued Ledvon. “Upgrades and options should have

Tips on rightsizing machine tools

Upgrading a machine tool? Here are Think about your future. What’s ahead some tips from machine tool experts: for your company 5, 10 years or more down First off, study the technology. The the road? Evaluate how the production builders themselves, via their Web sites, equipment you are considering will be can be a good place to start. Some of the adaptable to future automation. How more sophisticated technologies involve about refitting it in terms of software computing, software and materials development? science. Many machine tool What about tooling, fixtures, gaging builders offer courses in and other accessories? Is it better to shop machining technology. Be sure to around to various vendors for certain include your operators. items? Yes, said some experts. Investigate Consider partnering with an machine tool enhancements. OEM. This approach is not for Consider the sophistication level of everyone, but it can be helpful for your operators and employees on the shop some companies to share their business floor. Much of what is new in the machine plans and strategies with the machine tool tool industry uses highly sophisticated builder. CNCs and requires an equally high level Ask questions. Don’t be timid when of operator knowledge. Does the machine discussing new technologies with come with a training package? How much builders and options suppliers. You need retraining do you want to invest in? the optimal—not too little production Does the machine tool builder or dealer capability and not too much. Getting just have a local representative to help you what you need means learning about the should problems occur? How is their functionality and production capabilities inventory? What do other customers say of the machine tools you are considering. about them? –G. Weimer such effort allows you to avoid make it Rightsizing Machine Tools (continued) well worth it. prices that are published and realistic,” that real machine cost—corrected for As a bit of general advice, Mazak’s he continued. “Replacement costs of a inflation—has gone down every year for Yamane said, “Some people are merely machine might rely on the simple fact the last 20.” looking for cheap machines.” What is There are different patterns around the proper point of view when it comes contributors the world when it comes to deciding to rightsizing? “Affordable? Yes, but not on new equipment, added Mori Seiki’s if it means cheap.” GF AgieCharmilles Hyatt. “There are tax code issues. There Searching for just the right size ma- (847) 913-5300 are different business styles. There are chine tools can be tedious, but success www.agiecharmilles.com even political issues. In some countries, in getting that optimal machine is in the IS #340 you’re not sure what will happen. Then details. CTE there’s the issue of privately held com- Haas Automation Inc. panies and public companies. Public About the author: (800) 331-6746 George Weimer, a www.haascnc.com companies might need to consider a sig- IS# 341 nificantly shorter return on investment freelance writer based in for the new equipment.” Lakewood, Ohio, has an Mazak Corp. Machine tools today can be as techni- extensive background (859) 342-1700 cally sophisticated as advanced medical in the www.mazakusa.com equipment—or rocket science. Yet each industry’s business press. IS# 342 shop and factory that uses these pro- Contact him by e-mail at [email protected]. duction machines has a different set of Mori Seiki USA Inc. goals and a different style of doing busi- www.ctemag.com (847) 593-5400 ness. All the more reason to invest in www.moriseikius.com For more information, visit educating yourself and your colleagues IS# 343 “Articles Archive Index” and select about the technology. It may take a lot the “Machine Tools” category. of work and time, but the mistakes that

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