Branson Machine & Tool
On-machine probing cycles can reduce scrapped parts, rework
July 1, 2010
CIM explains how one Ontario job shop is using on-machine probing technology to reduce setup times and rework.
Branson Machine & Tool Ltd., Peterborough, Ont., can trace its roots to the 1930s fairly easily. After all, the company has been at the same location since the Great Depression when it made fishing reels.
Since that time the company has evolved into a full-service job shop servicing mainly the local area, but also farther away as well.
In 2003 the new owner, Don Hepburn, who had been an employee at Branson for more than 30 years, took over the company and started populating the shop with new, state-of-the-art technology to keep up with the changing needs of the machining industry. The company now has the capability to handle both one-off repair work and high-volume, CNC part runs.
At the same time, Hepburn’s son Paul joined the staff as the company’s vice president, keeping Branson Machine a family business.
“Most of our machinists have been with the company for many years, and their skill set is a major reason we can supply quality machined products to some of the largest manufacturing facilities in the area,” said Jason Rose, a 15-year veteran at Branson.
Complex, high-tolerance parts with short turnaround times are now the norm, and Hepburn and his staff knew that an investment in technology was necessary.
“We have a fairly good supply base as far as hiring skilled people is concerned,” said Rose. “Sir Sandford Fleming College is in Peterborough and Durham College is not too far away, and both of these have great skilled trade programs.”
Recently, in addition to the company’s existing machining technology, which includes sawing, manual mills, and CNC mills and lathes, Branson acquired new probing technology from Renishaw (Canada) to handle the measuring challenges posed by its machined parts.
“Quality control is paramount to everything we do, especially for our large customers like Siemens,” said Rose. “If our quality isn’t up to par, they simply won’t buy from us.”
With the addition of the probing, Rose said that production time has increased as the time it takes to check parts has been reduced.
“By adding probing systems to our machine tools, we have probably saved 50 percent in terms of setup time,” said Rose.
Inspecting a part while it is still on the machine means that the part doesn’t need to be moved. This inherently increases accuracy and also reduces the time it takes to measure the part’s critical features.
“When we bought our Bridgeport mill, I had never even heard of a spindle probe,” explained Rose. “But as I looked into it, and started to understand the technology a little bit, I realized that I could use it on nearly every job we run.”
Previously the jobs were set up using an indicator and an edge finder, and inspections were done using micrometers, bore gauges, and verniers. With the addition of probing technology, an inspection program is written for the part and is run with very little interruption of the production process.
“You spend time writing the inspection program, but this doesn’t compare to the amount of time that we now save,” said Rose. “We also seem to be getting more work now because of the quality of the parts we produce.”
Part quality improvements have allowed the company to get more work from existing clients, who are happier than ever with the work that Branson produces. This type of new work quite often can be easier to get, since the business relationship already in exists.
Downstream Benefits
A reduction in inspection time and improved quality are two of the easy-to-identify windfalls. A companywide reduction in scrapped parts means that both time and money are saved. In the past Branson would often order more material than necessary, expecting that some of it would be scrapped during the machining process.
Also, with improved equipment productivity and increased on time, the payback time for purchasing the machine tool itself has also been reduced.
“Morale is also definitely improved in the shop because the guys aren’t getting frustrated from scrapping parts,” said Rose. “We no longer get three-quarters of the way through a part, have to scrap it, and start all over from the beginning again, because we can prove very easily through the probing cycle that we are right.”
Probing Sequence
A typical application of the probing system on Branson’s floor occurs during the creation of a flange with a set bolt-hole pattern. The part’s diameter and thickness have already been turned in a lathe, and then the flange is bolted to the table.
At the beginning of every flange program a probing cycle is run that touches all four corners of the flange to correctly identify the centerpoint. Then the probes measure the diameters of the holes and the location of each hole in the pattern to make sure they are correct.
This is done at the beginning of each run, and then again about every 10 percent of the way through the run.
Measuring each hole can take 30 to 40 seconds, and measuring the bolt-hole pattern is typically done in less than two minutes. Prior to the installation of the probe on the machine, this process, complete with multiple tools being used, could take 10 minutes.
“It’s all in the old saying about teaching an old dog new tricks,” joked Rose. “Once you start using on-machine probing, you realize how much time you save and how accurate they are. To indicate a vise or to edge find a vise can take you 10 minutes. With the use of a probe, you can do it in two minutes.”
For more information, visit www.bransonmachine.com.
Probing Explained
Short turnaround times and small margins are two hurdles facing today’s manufacturers. Using proper part measurement techniques, including probing, can help
The demand for perfect parts is nothing new in the metalworking industry. However, manufacturers can take steps to reduce scrap, as well as the time it takes to check a part through the use of probing. The trick is to understand the benefits that can be realized.
“We frequently find customers who have a perfect application for a probe and just didn't know it,” explained Renishaw (Canada) Technical Sales Manager Philip Smith.
By involving a probing supplier early in the decision-making process, you can get tailored advice on the ideal probing hardware configuration for your job. Following installation of the hardware it becomes vital to undertake in-depth probe software training. This will ensure that the probing system seamlessly integrates with your machines and manufacturing systems.
“It is important to us that the customer immediately sees a benefit in owning one of our probing systems,” said Smith. “After all, they may come back and buy another, which is the case with Branson.”
The variables involved in choosing the correct probing system are as numerous and varied as machine shops themselves. However, there are some common themes.
Some typical needs are wanting to automatically find and set up a series of component datums both quickly and repeatedly; confirming critical feature dimensions before the part is removed from the machine; and setting up tool lengths and diameters automatically on the machine.
If a machine runs in a lights-out manner, probing can also provide feedback in the event that an error or crash occurs while running unmanned.
Collecting data and providing feedback are useful, however, only if they improve productivity.
“The No. 1 desire of shops is machine efficiency,” said Smith. “When this is achieved, then money is also saved, and I’ve yet to meet a shop owner that doesn’t appreciate that. Also, users of our systems can expect to see a reduction in scrap and rework, which also leads to saving money.”
One typical application of probing technology is for complicated metal aircraft parts, said Smith.
“Imagine if you’re making aircraft parts and have invested many, many hours of machining in one part made of an exotic material,” he said. “Reduction of scrap becomes very important to you.”
For more information, visit www.renishaw.ca.
Related Company Showrooms:
Renishaw Limited
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