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TIP 56 MoldMaking Technology —— OCTOBER 2017 An automated hard milling cell featuring two vertical machining centers tied to a common coordinate measuring machine (which is shown here), a modern control system with on-board interactive maintenance guides and the ability to probe workpieces in the machine can all positively impact the overall use of a shop. Using Automated Technology to Fill the Skills Gap MACHINING/AUTOMATION By Andre Ey Demand outpaces capacity for nearly all mold manufacturers in the current mar- ket. It's a good problem to have, but it's a problem nonetheless. Original equipment manufacturers are diversifying mold designs and introducing on-the-fly engineer- ing changes more frequently, so mold manufacturers must be more agile than ever. These challenges create the perfect storm for missed growth opportunities, particularly when combined with a deficit in skilled labor. Mold and die shops that embrace technology to improve the use of skilled labor, floor space and machinery are those that are best positioned to capitalize on growth opportunities. The artistry and expertise of seasoned toolmakers heavily influence the capabilities of traditional shops. However, as these veterans exit the market, so too do their valuable skill sets. Machine and process technologies have acquired vari- ous degrees of automation, which helps fill the gap. While machine tool principles have not evolved much in the past 40 years, levels of accuracy and reliability have. These changes make it possible for today's users to rely less on human adjust- ments and depend instead on machine performance. Advanced, continuous five-axis machining, for example, provides new levels of efficiency for intricate 3D molds. The technique enables mold shops to reduce cycle times and increase tool life while achieving precision contours with tight blends and matches. Innovations in accuracy and reliability like these enable automation and unattended manufacturing when a shop's lights are out, which increase a shop's use of its capital in turn. Shops that invest in superior technologies enjoy maxi- mized machine-utilization rates while they expand efficiency, improve quality and repeatability and mitigate the need for additional, skilled labor. To shorten the learning curve both for new and experienced operators, manufacturers should take advantage of modern control systems that feature on-board interactive maintenance guides, training videos and help buttons. Such technology leads to improved machine efficiency and helps a new genera- tion of operators produce parts quickly, reliably and efficiently. Coupled with automation hardware and software, these technologies give shops the ability to increase capacity without adding labor. This gives machinists the freedom to operate multiple machines, load workpieces and perform maintenance. Process automation is one of the fastest-growing strategies for overcoming capacity constraints. It does not matter if mold shops are performing small mold and die component pro- duction, large mold cores and cavities, hard milling or other machining. Automating processes means more than simply adding robotics. First and foremost, automation begins with an understanding of whether the intended machining process is stable enough for the change. Determining stability entails a detailed analysis of the goals a shop expects to achieve through automation, including the impact on the overall use of the shop. It can be as straight- forward as automatically establishing offsets by probing workpieces in the machine or as multifaceted as deploying a fully-automated system with machining, metrology and part- storage systems in one cell. Enlist an experienced application and engineering services provider to help determine the most appropriate machine tool and automation options. The services provider can help a shop to capitalize on what's next in moldmaking and raise its com- petitiveness by overcoming process challenges and increasing the use of its equipment, shop floor and labor. CONTRIBUTOR Andre Ey is vice president of Makino Die Mold and EDM Technologies. Image courtesy of Makino. FOR MORE INFORMATION Makino / 248-232-6203 andre.ey@makino.com / makino.com