Larry Schwartz, President of Okuma America described how the Partners in THINC facility was created and explained that efficient and effective machine tool solutions require a complete understanding of the customer's production process, their challenges and their goals. He described how the Partners in THINC facility provides a one-stop opportunity for manufacturers to present their toughest production problems and have them solved by a multitude of experts in machine tool technology and peripheral equipment. This collaboration is possible because of the open-architecture of the THINC control. The needs of customers are driving the capabilities of the THINC control as they bring new problems and challenges to be solved.

Travis Blackburn (left) and Mark Elmore (right) of Morris South stand with Glenn Capwell of Southern Prestige as Glenn shows off his iPod Touch door prize.

Attendees were treated to a live demonstration of Sandvik tooling on an Okuma MB-46V vertical machining center and had the opportunity to meet with other Partners in THINC members to discuss workholding, gauging, bar feeders, high pressure coolant systems and more. Partner presentations included the automated oil coupling cell featuring a Fanuc robot, presented by Andy Anderson of Gosiger Automation and adaptive software presented by Caron Engineering. Morris South representatives were on hand to help answer questions and identify partners for solution development.

Scott Janus, Dan Arrington and Mike Dunn hold their door prizes from Partners in THINC.

Scott Janus of TurboCare stated that his company sends people to the events at Partners in THINC to get exposure to the tools and technology available from the partner members and that, "there is a lot of talent here." He enjoyed the opportunity to see and talk to vendors such as Renishaw and Marposs.

In addition to presentations and demonstrations, attendees were treated to lunch, door prizes and a facility tour.

Okuma and Morris South welcome the chance to work with manufacturers to solve their toughest problems. The Partners in THINC facility is open Monday through Friday from 8am to 5pm. Tours and meetings can be scheduled by contacting Kathy Poulin (Partners in THINC) at kpoulin@okuma.com or Mark Elmore (Morris South) at melmore@morrissouth.com.

About Okuma America Corporation:
Okuma America Corporation is the US based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology, founded in 1898 in Nagoya, Japan. Known for its technology leadership and world-class manufacturing, product quality and dedication to customer service, Okuma strives to be the machine tool solution provider to manufacturers worldwide. Fore more information, visit www.okuma.com

About Partners in THINC
Partners in THINC is a unique facility and concept offering integrated solutions and a one-stop-shop designed to streamline current manufacturing processes, improve capabilities, or for exploring advanced manufacturing options. Each member of Partners in THINC brings specialized equipment, expertise and a commitment to provide the best possible integrated solutions to the end-user. For more information, visit www.partnersinthinc.com.

During their visit, students were treated to an actual cutting demonstration on an MB-46V vertical machining center as it performed a die/mold cut. They were also given a presentation on the characteristics needed to succeed in the manufacturing world. Presenter Jeff Estes, Director of the Partners in THINC facility, stated, "At this age, kids don't really understand the breadth of occupations and job opportunities available in the manufacturing sector. Camps and trips such as these expose them to industries and possibilities they otherwise might not see. We feel it's important to provide this type of community service in order to keep our economy strong and growing."

About Okuma America Corporation:
Okuma America Corporation is the US based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology, founded in 1898 in Nagoya, Japan. Known for its technology leadership and world-class manufacturing, product quality and dedication to customer service, Okuma strives to be the machine tool solution provider to manufacturers worldwide. Fore more information, visit www.okuma.com

About Partners in THINC
Partners in THINC is a unique facility and concept offering integrated solutions and a one-stop-shop designed to streamline current manufacturing processes, improve capabilities, or for exploring advanced manufacturing options. Each member of Partners in THINC brings specialized equipment, expertise and a commitment to provide the best possible integrated solutions to the end-user. For more information, visit www.partnersinthinc.com.

Attendees had the opportunity to see Okuma machine tools in action and to meet with various supplier partners to discuss advanced manufacturing and the integration of machine tools with peripheral equipment. Companies represented at the event included Iscar Metals, Sandvik, Schunk, Zoller and others. In addition to talking with manufacturers, attendees heard Dr. Bert Erdel, Ph.D. speak on "A Wholistic Approach to Machining". Lunch was provided and door prizes were awarded throughout the day.

Okuma and Morris South employees demonstrate the Kennametal ToolBoss

When polled after the event, 100% of the attendees stated that the Productivity Improvement Day was a valuable use of their time. They welcomed the opportunity to meet with multiple vendors in the same location and discuss how the components could work together to improve productivity in their shops. The next Productivity Improvement Day will be held on April 29 and will focus on Multi-tasking, multi-function machines. For more information contact Kathy Poulin (Partners in THINC) at kpoulin@okuma.com or Mark Elmore (Morris South) at melmore@morrissouth.com.

About Okuma America Corporation:
Okuma America Corporation is the US based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology, founded in 1898 in Nagoya, Japan. Known for its technology leadership and world-class manufacturing, product quality and dedication to customer service, Okuma strives to be the machine tool solution provider to manufacturers worldwide. Fore more information, visit www.okuma.com

About Partners in THINC
Partners in THINC is a unique facility and concept offering integrated solutions and a one-stop-shop designed to streamline current manufacturing processes, improve capabilities, or for exploring advanced manufacturing options. Each member of Partners in THINC brings specialized equipment, expertise and a commitment to provide the best possible integrated solutions to the end-user. For more information, visit www.partnersinthinc.com.

Lyndex-Nikken's Ultra Large Bore (diameter 205 mm) Rotary Table is the answer to large diameter bar work and oil patch applications. One of the newest additions to its rotary table product line, the CNCB450 features a large through hole and a powerful clamping system.

The Ultra Large 8" diameter thru hole and the rigidity of this Nikken rotary table offers new innovative solutions to the Oil Patch industries' large pipe applications.

Supplied by Lyndex-Nikken, Nikken rotary tables are designed with a unique and patented carbide worm system. The carbide worm system incorporates a carbide worm screw and an ion nitrided worm wheel, rather than a conventional bronze or bronze alloy actuation mechanism. The result is a reduction in friction and wear by up to eight times. The worm screw consists of a less brittle V-grade form of carbide, while the worm gear is ion nitrided to a depth of 0.1 mm and an external surface hardness of 68 Rc. These properties, as well as a steel way hardened to 58-60 Rc, all work to enhance system rigidity and longevity, and make Lyndex-Nikken rotary tables ideal for high-speed, high-accuracy rotation.

With a premiere booth and concept at IMTS 08, Partners in THINC reproduced a full manufacturing facility in a mere 4,800 sq. ft. of space, producing a model air-cooled engine assembled and boxed for shipping by robots.

Not only did the cell demonstrate a vast number of equipment capabilities from Okuma and more than 20 participating Partners, but most importantly, it showcased process flow - complete from order entry to shipment invoicing - all through the THINC control.

In a nutshell, six different cells produced a total of 10 parts in a cycle time of approximately 33 minutes. Though a manufacturing engineer collected the individual parts from each machine to take to the robots to assemble due to space restrictions in the booth, this process could be automated by parts catchers, automated guided vehicles and/or conveyors according to Jeff Estes, Director of Partners in THINC.

"It takes about 17 minutes for the two FANUC robots to assemble the motor and package it," said Estes. "This includes thorough inspection of every component by the FANUC vision system, including fasteners, and then putting the completed product into a box. Now, human hands do actually close the box, insert the packing list and the invoice generated by SAP and/or JobBoss - we're using both - and then the pre-printed FED-EX label is applied. This process could also be automated with further investment into available packaging and shipping systems - I'm thinking about $30,000. We just didn't have the space at IMTS to do this."

Partners in THINC and the Power of THINC
The concept of Partners in THINC is built upon the Okuma THINC control (THe, Intelligent Numeric Control), an open architecture, Microsoft Windows-based platform, and how more than 30 Partners collaborate through the Charlotte, NC facility to bring out the best of the control's capabilities for their advanced manufacturing customers.

"The THINC control is Ethernet-ready and offers plug-and-play compatibility to Okuma machine tools and industry peripherals required in manufacturing," said Estes. "The control is designed to optimize productivity through the availability and adaptability of real-time information for our end-users."

Taking the process and capabilities of Partners in THINC to the next level and showcasing the collective strengths at IMTS was the vision of the Okuma America Corporation Engineering group.

"The vision of the Partners in THINC Booth is simple," said Brian Sides, Director of Engineering for Okuma America Corporation. "For the first time ever, collaborating Partners are presenting our customers with a real factory setting within a trade show setting - right down to not having carpet - which demonstrates the reality of business, automation, and quality systems connecting and communicating to provide productivity improvements and real time visibility of the manufacturing process from order entry through finished goods shipment."

Connectivity
The THINC control is compatible with SAP Manufacturing Integration and Intelligence (SAP MII) platform creating "seamless connectivity" between all machines and systems without additional engineering required, according to Bryan Newman, Director of Information Systems at Okuma America Corporation.

"SAP MII is an example of a perfect match for making Okuma machine tools the most efficient and adaptable on the market," explains Newman. "Customers can get a unified view of manufacturing data through synchronized manufacturing operations and back-end business systems. Being able to access data and analyze opens up opportunities for greater efficiency and mitigates operational risk."

Exact Software's JobBoss program is also used to demonstrate an alternative for an ERP system - a lower cost option to SAP MII.

"Exact understands the competitive pressures job shops face in learning how to maximize business performance by bringing together seemingly unrelated processes into a cohesive system to build their shops more effectively," said Newman.

Equipment Integration
With the Okuma machine tools and THINC control at the center of each cell of this simulated manufacturing facility at IMTS, Partners who demonstrated include: Marposs, Exact JobBoss, Midaco, ISCAR, Sandvik Coromant, ABB Robotics, Kennametal, Gosiger Automation, LNS Turbo, Shell Lubricants, Renishaw, FANUC Robotics, Caron Engineering, SAP, Schunk, Royal Products, Blum, Extrude Hone, BigFix, Symantec, Trend Micro, WebEx, ChipBLASTER, Zoller, IEMCA, and Infinity Rebuild.

Highlights of the Partners in THINC booth include a process that begins with the MB56-VA that produces the head and connecting rod on the 3-axis vertical machining center. A Midaco pallet changer is utilized to maximize spindle cutting time and Renishaw On Machine Verification (OMV) software and probing systems are utilized for quality assurance. The ChipBLASTER high pressure/high volume coolant system ensures high production and thorough chip removal. The Extrude Hone ECM CoolPulse proceses unwanted material without harmful, corrosive compounds on the head component.

The engine case and cylinder were machined complete on the 4-axis HMC MA-400H with a Fastem container system that demonstrated the ability to load multiple jobs onto the cell with almost zero change-over time from one part to another. Marposs provides 3DSI, CAT40 Probe and Quick SPC software that are compatible with the THINC control. In addition, there are two choices for tool management systems.

"If a system like this was purchased, the customer would have a choice between the ISCAR Matrix or Kennametal ToolBoss tool management systems which are shown here at IMTS," said Estes. "They are both compatible with the THINC control and the Zoller presetter. It's just a matter of the customer's preference, and we want to give them options."

A timing pulley was machined complete on the 4-axis LU-400M lathe with milling function turret. The IEMCA bar fed material extends unattended operation while the Marposs post-process Bluetooth gauging ensures part compliance. Caron Engineering's AutoComp software automatically controlling tool offsets and tracks toolwear. The Twin Millac 33T machine cell utilizes multi-function vertical machines to complete the Op 10 / Op 20 piston. An ABB robot loads, transfers and unloads to and from both machines through special automated doors integrated by Gosiger Automation. Both Sandvik Coromant (tooling) and Kennametal (tooling and rotating tools) are used for metal removal.

The crankshaft and the spark plug are produced on the LT-200MY through integration of the Gosiger Automation slider system with FANUC Robot which will load/unload the crankshaft while the spark plug is bar-fed by the LNS barfeeder. Caron TMAC7, a tool monitoring adaptive control application created by Caron Engineering, monitors spindle horsepower in real time during the cutting cycle. It is capable of dynamically adjusting axes feed-rate to maintain an optimum torque curve for each cut, thus maximizing tool life, minimizing cycle with the ability to monitor coolant flow to insure steady tool load through each pass.

The display base for the model engine was machined on a re-furbished LC-40, 4-axis lathe from Infinity Rebuild that was originally manufactured more than 20 years ago. The LC-40 was upgraded with a THINC OSP-P200 control, making it more compatible with the refurbished ABB robotics cell and the entire ERP system. Trumpf laser marking was used to add logos to the base (and a serial number to the piston), but can be used for any marking requirements on metal surfaces according to the manufacturer.

Assemble and Ship
Two FANUC robots, integrated by FANUC robotics, assemble all the components manufactured in the Partners in THINC booth to complete the model air-cooled motor and package it for shipping. Customers who registered to win were randomly selected to receive units produced daily by swiping their IMTS badges at eight or more Partner booths who featured the THINC control simulator, all linked via internet according to Sides.

"We are shipping finished motor assemblies daily from the Partners in THINC booth per a production and assembly schedule for customers who place orders generated by visiting our participating Partners' booths," Sides says.

"Pulling this together within a trade show environment is a testament to the power of collaboration of Partners in THINC made possible by the intelligence and openness of the OKUMA THINC control," he adds.

Read More | See More Solutions

Okuma America is pleased to offer our customers increased information management capabilities thanks to the joint efforts of Okuma and SAPAmerica, Inc., the newest member of Partners in THINC.

Through this partnership SAP's Manufacturing Integration and Intelligence (SAP MII) application will be merged with the power of the THINC OSP to create a seamless information exchange solution. As a result, business operations will be directly connected to the plant floor allowing for immediate, real-time flow of mission-critical data between the manufacturing equipment and the business office. This solution, which is a perfect example of the collaborative nature of Partners in THINC, answers customers' demands for even greater efficiency and control in the manufacturing environment, ultimately improving bottom line results.

By merging SAP MII with the THINC control, Okuma and SAP enable customers to experience reduced operating costs, increased return on asset usage, improved compliance and quality standards and an improved ability to meet both internal and external production demands. Because this solution puts the necessary information directly in the hands of those who need it, when they need it, and allows individuals to act upon real data, the potential for process improvement and increased performance is unprecedented. The result is an even greater competitive advantage for Okuma customers.

This agreement is made possible by the shared visions of Okuma and SAP. Both companies are committed to focusing on core competencies and leveraging partnerships to achieve results for our clients. Partners in THINC is the ultimate setting for such innovation and collaboration. As a result, our customers can let their imaginations and expectations soar. There are no limitations to the thinking of how to use the power of SAP business solutions or the power of third- and fourth-party hardware and software through the Okuma THINC control.

Doug Noxell, Technical Advisor and Consultant for Gosiger 3D, LLC (Plymouth, Michigan) explains how older technology will impede your business in a competitive global market and how to invest properly in mold making equipment. "To be successful, you first have to eliminate as much labor and as many operations as possible," said Noxell. "By having the correct tools, whether cutting tools, the machine itself and/or the software, these items are necessary for the speed and accuracy required in today's market. If you can do all of this and run unattended, then your cost will go down and the better quality and accuracy will go up as a result. The bottom line is making a better product for the customer."

Simply put, the older the technology, the more manual labor is used which costs more money in the long run. Whether the labor is in operating the machine, secondary operations such as polishing or hand work, the best way to reduce costs and get the piece delivered more quickly is to cut as much manual labor as possible.

The older technology refers to CNC machines usually eight or more years old with slower rpm's and that have no software on the machine to control acceleration and deceleration. This doesn't mean that there aren't new machines still made using this outdated technology. Making large heavy cuts at slow federates was the norm at one time. However, the slower spindles with the higher horsepower cause poor tool life and poor surface finish. Old-style tool holders include ER collets systems and the endmill holders with set screws. The runout and balance on these holders is not suitable for tool life or surface finish.

"And that's when it's time to replace that outdated Hurco with a new Okuma or other high-end machining center," said Noxell. "Features on these new machines can create labor cost savings through the use of tool changers, tool lasers and proper cutting techniques which means more volume with the same staff."

In a typical production-type environment, cost justification for a per-part piece is fairly black and white: A shop needs to produce X many parts, so they purchase X equipment. However, in a mold making environment, it's much more difficult because the end product goes through many different areas throughout the shop.

"If you look just at the machining portion, faster is not necessary cost efficient," explains Noxell. "It's not just the hours on the machine; it's all the secondary hours or operations such as EDM or polishing that need review. The true cost of ownership is the total cost to produce your mold insert and that includes how much money is saved reducing secondary operations."

For example, if you currently machined a core or cavity insert on your traditional CNC machine in 50 hours at $65 an hour ($3250) and added approximately $300 for consumable tooling costs, two days of polishing (16 hrs X $50/hr) at $800 and one day of spotting at $400 (8 hrs X $50/hr) your total cost for production would total $4750.

Investing in newer technology would reduce your production costs by 25% by decreasing machine hours to (30 x100= $3000), consumable tooling costs to $200 and spending fewer hours polishing (5 hrs x $50 = $250) and spotting (2 hr x $50/hr = $100).

The consumable tooling lasts longer when used in the higher quality machines. The simple fact that you spend less time changing tools is a savings not to mention the ability to cut an entire part with one tool for 20 or 30 hours with no blends from tool wear.

If EDM is required, it may be possible to machine these details using newer equipment for even further savings. When companies try to cut ribs and small features with older technology, it is not cost efficient due to the existing machine quality. The new high-speed machines are capable of cutting very small details that were previously produced using EDM.

With current technology, the finish and accuracy that will allow that mold to be closed, and spotted together (closed off to make the part) will happen much quicker according to Noxell. "Years ago, we used to put a mold into a spotting press and we'd spend a day to two days hand-grinding and fitting this mold together. Now when we cut these parts to the accuracies that we do, it's down to hours instead of days. That's pretty significant. Knocking two days off your delivery time saves you time and money."

Running a machine unattended, overnight may not provide a cost savings if the older technology is only running one tool to complete the job. "People would say to me that they were doing lights out with their older machines. However, it was just because their programs took so long to run. They would leave the machines running, but at a reduced feed rate to be safe, etc. The companies felt they were getting something for free, even though it was a very low productivity level compared to the true, unattended, lights out facilities that we talk about today."

When it comes to looking at finance costs, purchasing a higher quality machine will lower the monthly payment because the finance company will usually offer a higher residual compared with the less quality machines based on the true resale value.

Examples:

Fair Market Value
As of 12-1-07
$100,000.00
Hurco VMC
60 months @ $1,596.05, in advance
Residual of 23%

Fair Market Value
12-1-07
$200,000.00
Okuma VMC
60 months @ $3,015.78, in advance
Residual of 29%

Fair Market Value
12-1-07
$200,000.00
Hurco VMC
60 months @ $3,192.09, in advance
Residual of 23%

So when should you buy?

Depending on the status of the equipment, Noxell suggests purchasing at least one new piece of equipment if you are currently using outdated technology and replacing current technology every two to three years. "If you have a quality piece of equipment that is only two to three years old, it holds its value very well. When it's time to upgrade, it's very easy to trade up - much like leasing your car. The people who don't invest in newer technology just can not compete and they may slowly die off. Those who do invest seem to stay busy, and thus competitive."

Essentially, if you want to stay with the new machine technology because it is giving you all of these added features, if you keep flipping these machines over every three years, you'll find that the cost will go down over time, because you are just paying the difference between the two. Trying to replace five machines at a time is a very large investment to make at one time which is not cost effective for most small mold shops.

Rising labor costs, the demand for less finishing time, quicker turnaround time, and improved surface finished have all been driving the tremendous advances that have been made in the machining industry these past 10 years. Where does it go in 10 more?

Industry Changes
According to Okuma America Corporation (Charlotte, NC) COO and President Larry Schwartz, the changes that have occurred in the last decade go beyond 10 years-to 15 or more. "Quite frankly, we saw a lot of manufacturers moving offshore looking for lower cost dies and molds for the industry back then," he recalls. "For some time, the qualified finished die or mold with the technology that had been available was very labor intensive, and the level of expertise that existed in the United States also was dwindling at the same time. Though there was a fair enough amount of developing technology during that period of time mostly around the EDM, wire EDM technology and ECM (electrical chemical machining); these also were very costly. The issue was that almost all of the dies or molds needed a great deal of handwork to achieve the finishes, shapes and smoothness of contours that were required to get the product out of those dies or molds to the level of quality that they were looking for.

"During all of those 10+ years, CNC manufacturers probably lost a considerable amount of that business-with exceptions, of course," Schwartz continues. "I believe that the technology that we have been introducing as an industry as a whole has been seeking ways to minimize the handwork required to make a finished die or mold. To do that there was some sophistication that was desired in the machine tool design and I'll use the terms of thermo stability or thermo-friendly that would be required to maintain the finishes that would be needed to eliminate hand polishing. The goal has really been to have zero handwork. The question is to what level can one go into metal removal-using today's technology-to eliminate that. I personally believe that if we have reached it in some areas, but maybe in time we will reach it in all areas. The combination of control technology, servo controls and the whole balance of mechanical devices-along with some developments in spindle designs and characteristics-has created the opportunity to eliminate a lot of handwork and will continue to improve."

According to Okuma America's Schwartz, the company has focused on thermo stability and has won numerous awards for designing a very stable, rigid, strong platform. "We have some very special thermo control capabilities where we are making machine position changes automatically based on thermo compensation, and along with that came some additional Super NURBS which dealt with processing speeds," he states.

"One of the things that I think most people run into when they are doing exotic, elaborate molds or dies is that the amount of data crunching that goes on is unbelievable," Schwartz continues. "In many cases, the programs are so extensive and so long that many controls have a problem retaining all of that data in their platforms. Therefore, the information is streamed from a major mainframe design computer that is feeding data to the machine tool as it is being consumed. Delays in information and flow can potentially cause issues with getting the transitions and geometry shapes in the speeds that one would like because one just can't transfer information that fast. I would say that with our new control, its processing speeds have been improved, and with our Super NURBS capability, allow us to move at very rapid rates with very fine, very exotic geometries. Along with thermal stability we have created what we'd say is probably a finished product out of the machine tool with very little, if any, manual polishing or deburring."

Future Challenges
In a market that clearly is rising to meet the current demands of the industry, what does the future hold for machining manufacturers and suppliers? Schwartz of Okuma America believes the outlook is bright. "As we advance machine control processing speeds, increase solid modeling ability, create a die from its CAD/CAM environment, and download it directly to the machine tool with little or no operator intervention, we will streamline the whole process from the initial product out of a mold to the calculations dealing with what the true mold geometry is based on: shrinkage, materials used, and how do you drive the program using all the SuperNurbs that we have available," he states. "To really yield from beginning to end a very seamless process of a finished product off of the machine tool, I believe that we will eventually achieve 100 percent of our goals.

"I believe it is well within the next 10 years that computer technology, the servo controls and the onboard computer processing machines speeds of the machine tool will work together to create a truly finished product," Schwartz continues. "We are investigating the use of higher end chips that go even beyond the finite analysis engineering that would help us achieve our goals in both the collision avoidance technology and in processing speeds to get even finer geometry, faster moves and create a real seamless process from beginning to end. Our ultimate goal is to move at speeds beyond our comprehension right now. So I think we are on the level and stream of continuing our progression of advanced processing speeds to the next level."

Some plants I visit are really exciting - they have embellished the technology that is available with many levels of success. They push the envelope and are thinking outside of the box, finding new and perhaps less conventional processes for manufacturing more efficiently and effectively. Then there are the other customers that support the old saying, "if it's not broke, don't fix it." While you can see a transition in their plants from old equipment to brand new or relatively new equipment, you can quickly recognize that their methods of processing or manufacturing components haven't changed in 15 or 20 years. What they are really doing is buying today's technology that supports their old methods of manufacturing.

In regards to the latter customer, some of this comes from "they only know what they know." Employees that have worked together for 20-30 years can be very successful, however, they may also start to feel the pinch that comes from global competition and wonder how anyone can make a part better or faster than they have after all of this time in the business. Many of these same customers don't appear to invest much into their people by sending them to shows, open house events, seminars, or even participate in free webinars online. They miss the opportunity in some means to visit other manufacturing companies surrounding them - in and outside of their markets - to learn how to apply technology in new ways.

Now take into consideration that the supplier has previously visited a customer. The customer requests information on a particular machine, asks when it's available and to please deliver a quote. The supplier/sales engineer does as requested, and honestly believes he's doing a service. I know because I've asked. I've asked what is the machine for, what is the customer going to make, and how do you know if the requested equipment is right for the job? When the response is 'because that's what the customer asked for, and I'm giving him exactly what he wants.' I find myself asking, "So, now you're a mailman?"

What I'm hearing is that despite all the knowledge and expertise possessed, the supplier/sales engineer chose to give the customer what he wanted and just deliver a quote. I agree we want to make the customer happy. However, this is where we, as suppliers, have an opportunity to show the customer what he really needs; to give the justifications as to why it is not only better, but is more effective for the benefit of their business. As a result, we can start providing a value and be an extension of the customer's manufacturing thought process - just by sharing our expertise and knowledge.

Because customers face many manufacturing challenges and pressures from competition all over the world, being aware of technological advances can provide a competitive advantage. For example, knowing how to potentially reduce direct labor costs or find better ways to look at standardizing of raw materials could afford customers some big benefits. However, many customers may not know what questions to ask or what they really need. Maybe the supplier needs to ask more questions of the customer to understand what he was trying to accomplish with the investment he was making.

If as suppliers we can get customers to start thinking a little differently in order to stay more competitive in a constantly changing market, perhaps we can add value to the manufacturing industry instead of just being mailmen. To make a long story short, it's worth taking a little more time to understand what an individual's needs are before you arbitrarily deliver him what he wants, because you may have helped him go out of business when you thought you were helping him stay in business.

Larry Schwarz is the President and COO of Okuma America Corporation, Charlotte, North Carolina.

Chicago, Illinois, September 9, 2008 - Okuma America Corporation and Partners in THINC today announced an agreement with SAP America, Inc. that merges the technology of the power of THINC with the SAP® Manufacturing Integration and Intelligence (SAP MII) application to create a seamless solution for end users. The agreement allows manufactures to achieve the "perfect plant" in real time by merging business and manufacturing systems together to reduce operating costs, increase returns on asset usage, achieve compliance and quality standards, and meet the internal and external needs of their customers.

SAP had already recognized the pressures manufacturers faced on a daily basis and created the SAP MII product to connect the SAP ERP application to the plant floor in real time and deliver actionable intelligence to production personnel. The comprehensive solution provides both manufacturing intelligence and integration, extending the functionality of the SAP NetWeaver® technology platform onto the real-time plant floor to significantly lower the total cost of ownership on manufacturing systems infrastructure. Microsoft Windows compatible, the SAP software can be installed on THe Intelligent Numeric Control (THINC) to bring the power of SAP solutions directly to Okuma users.

"The handcuffs are off," said Okuma President and COO Larry Schwartz. "There are no limitations to the thinking of how to use the power of SAP business solutions or the power of third- and fourth-party hardware and software through the Okuma THINC control. This agreement allows the customer to generate real-time, timely data to improve their efficiencies, and gain a competitive advantage - from the shop floor to the boardroom."

The THINC control is the central force behind Partners in THINC, located in Charlotte, North Carolina. The facility features partnerships from more than 30 industry leaders who work together to provide real-world, integrated manufacturing solutions for the Okuma end-user. Members of Partners in THINC integrate their equipment and software solutions through the plug-and-play capable, Ethernet-ready THINC control to streamline manufacturing operations, cutting time and costs in the process. As a new partner of Okuma, SAP will be able to integrate directly with the THINC control instead of relying on a stand-alone computer to provide the necessary link.

"The addition of an Okuma THINC connector for use with SAP MII added to the already numerous prebuilt, standards-compliant connectors will allow more customers to attain SAP's vision of the perfect plant," said Grant Bodley, vice president, Discrete Industries, SAP America. "This will help bring together core SAP solutions with the software, hardware and services offerings of ecosystem partners to drive innovation for discrete manufacturers."

Schwartz is confident that the advanced technology that Okuma has developed and the vast knowledge and experience that SAP brings to the table will be of great benefit to manufacturing customers.

"Our companies will now, for the first time, bring the two worlds together and providing the manufacturing arena and the business arena real-time, timely information - information they can act and improve upon," Schwartz said.

What customer doesn't want better utilization of equipment, better understanding of what is happening in the plant in real time to provide better and faster deliveries to customers? For more information, visit www.partnersinthinc.com, www.okuma.com or www.sap.com.

About Okuma
Okuma America Corporation is the US based affiliate (Charlotte, NC) of Okuma Corporation founded in 1898 in Nagoya, Japan. Only Okuma engineers and builds each component on every machine including the Automatic Tool Changer (ATC), motor/drive/encoder, base casting, turret, spindle, and the Microsoft Windows-based, THINC-OSP control. Okuma offers vertical and horizontal machining centers, lathes, double column machining centers, grinders, and wheel machines to meet a wide range of industry needs. For more information, visit www.okuma.com.

About Partners in THINC
Partners in THINC is a unique facility and concept offering integrated solutions and a one-stop-shop designed to streamline current manufacturing processes, improve capabilities, or for exploring advanced manufacturing options. Each member of Partners in THINC brings specialized equipment, expertise and a commitment to provide the best possible integrated solutions to the end-user. For more information, visit www.partnersinthinc.com.

SAP, SAP NetWeaver and all SAP logos are trademarks or registered trademarks of SAP AG in Germany and in several other countries.

All other product and service names mentioned are the trademarks of their respective companies.

SAP Forward-looking Statement
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A machining cell combines lathes, a robot and a conveyor system to enable automated production of precision oil-drill couplings.

The good news for shops serving oil and energy companies is that they are busy. The downside to this is they often don't have time to research and integrate new machining strategies because they are running at full capacity, suggests Gayle Vollmer, Okuma's director of technical resources.

Take the manufacture of couplings used to join lengths of oil drill-pipes. Coupling machining has traditionally been performed manually, with operators loading workpieces into relatively old equipment. These heavy couplings are difficult for operators handle, and chip control during requisite turning and threading operations can be a challenge. Plus, the couplings' ID, OD and threads must be accurately machined so that the pipes they connect don't leak.

Until recently, an automated system dedicated to manufacturing those couplings hadn't been created, Mr. Vollmer says. Because demand for precision couplings is increasing, however, Okuma and the Partners in THINC collaborative decided to develop an automated coupling production cell using vertical and horizontal lathes, a gantry robot and a conveyor system.

The cell was built and tested at the Partners in THINC facility in Charlotte, North Carolina. After experimenting with various tools, coolants, coolant pressures and machining practices, the Partners were able to solve the primary problem of chip accumulation during the turning and threading operations.

Unattended Coupling Production

The automated manufacturing process begins with a FANUC overhead gantry robot that loads double-length coupling blanks in and out of the machines. The overhead gantry design saves valuable floor space.

The roughing and finishing operations for coupling ID and OD are performed on a four-axis Okuma LOC-650 oil-country lathe. This lathe also performs the cutoff operation that separates the blank into two 10-inch-long couplings (the finished coupling below has a diameter of 9 5/8 inches). The workpieces then move down a conveyor to an Okuma Konan V80R vertical turning lathe (VTL). The V80R's vertical spindle orientation assists in evacuating chips during turning and threading operations. Both machines are fitted with a Schunk "oil country" chuck.

The chips produced during threading operations fall and flow away from the workpiece thanks to the V80R's modified tooling adapter and ChipBlaster high-pressure, high-volume coolant system. Coolant flow from precisely directed nozzles helps break up the chips and flush them out of the machine. After the threading operation, the workpiece is conveyed out of the cell and delivered to a measuring station, where a Marposs gage inspects its threads and diameters. The cycle time to turn, thread and deliver a completed coupling out of the cell is only 11 minutes.

This cellular production method allows complete OD turning in one operation. This helps meet high-precision threading requirements by avoiding the undesirable blend line that occurs with a two-part operation. In addition to increasing production speed, the cell eliminates the need for a 1- to 2-minute sawing operation.

Korn, Derek. "Automated Production of Oil Drill Couplings." Modern Machine Shop. January, 2008, pp 102-106.

For the high-speed machining manufacturing industry, these create infinite possibilities with some clever programming to decrease tool wear and breakage, a die-and-mold operation has found.

The customer's initial specification requirements became an opportunity to improve high-speed machining efficiencies through creative partnerships and effective use of new technologies.

The die-and-mold industry is constantly searching for a balance between tool life, heat generation, and cutting speeds. A die-and-mold operations with 3-D specifications required its Okuma MB-56V to be set up for high-speed cooling interface and variable psi pressures. It found a multitude of resources for fine-tuning it's high-speed machining processes to save tool wear and maintain increasingly tight tolerances.

Partners in THINC collaborators Okuma, Blum LMT, INC, ChipBLASTER, and Caron Engineering applied creative technologies and programming to enable the operator's spindle psi variable requirements and provide the ability to monitor coolant flow and pressure. But they also push the envelope on what their combined technologies could really do - a considerable upgrade ready for plug and play compared to the customer's previous standards.

Starting small

When cutters become very small, high pressure becomes a problem. According to Doug Noxell, technical advisor and consultant for Gosiger 3D, LLC, the ability to use small cutters and go much faster has to do with the Super-NURBS (Non-Uniform Rational Basis-Spline) functions - or acceleration/deceleration ability that should be standard on all high-speed CNC machines.

"Flexibility is key here," explains Noxell. "For instance, an operator can up the tolerance for roughing operations or tighten it up for a finishing operation. While tightening up may slow the machine a little bit, it is just enough to hold the accuracies to spec."

Originally, the coolant pressure on the high-speed vertical machining center was controlled based on the load on the spindle, which works fine for larger tools. However, when using the smaller tools to follow a 3-D shape, Super-NURBS controls are necessary to feed based on holding accuracies at required tolerances that can be set on the control.

ChipBLASTER, a world-renowned company that leads the high-pressure coolant industry, created a software solution to recognize which tool was currently in the spindle and would vary the pressure requirement according to the tool application. In the past, the ChipBLASTER interface allowed for a solid 1,000 psi, through-spindle coolant on every single tool used unless a special-ordered, four-pressure factory pre-set option was purchased. The 200, 500, 600, and 700-psi pre-sets were permanent unless changed by a factory representative.

By reducing the pressure to match the application, the coolant pressure now matches each tool placed into the spindle. Utilizing the application programming interface (API) and the plug and play Ethernet capabilities of the Okuma THINC-OSP control, clever programming yielded positive results. Now an infinite number of modifiable pressures can now be set for each individual tool, cutting down the waste of energy on the coolant pump as well as avoiding too much pressure on the tool.

Thermo stability is another important factor to consider in tool life management. In this application, the MB-56V utilized two features: thermo distortion of the head and the spindle (TAS-S), and thermal distortion of the actual machine itself.

"In other words, if the temperature of the room goes up, or when using the ChipBLASTER coolant and the temperature decreases, it monitors and thermally compensates for any inaccuracies that would be there," explains Noxell. "The casting would naturally expand with a rise in temperatures, changing the part dimensionally. There are sensors on the MB-56V machine that actually monitor the temperature of the casting and then compensate for any thermal growth."

Laser automation

Having to stop the spindle to measure or replace broken tools was costing the customer valuable time and money.

A Blum laser tool setter was integrated through the MB-56V THINC-OSP control to allow unattended machining and efficient tool management. According to John Sherrick, National Sales Manager for Blum LNT, Inc, the laser tool setter is a multi-functional device ideal for high-speed machining.

"If a tool has a lot of run out, which you would normally have in cavity machining on a three-dimensional application, the laser tool setter can verify that the tool is in a certain concentricity limit," explains Sherrick. "The customer now has the ability to measure corner radiuses of the tool and to determine that multiple inserted cutters are not broken or chipped and can assess and direct tool management. The device also checks the cutting tool's edges so tool breakage can be detected before it becomes a problem - all without operator intervention."

Tools are now measured in-process and include measuring the length of the tool while the tools are rotating at the dynamic operating speed of the spindle. The tool setter measures the smallest of tools to monitor tool breakage, requesting another tool as needed or stopping operations before any damage occurs.

Adaptive control

The Okuma THINC-OSP control offers a graphic interface that can simulate the actual tool path run before it actually runs the tool path on the machine, eliminating errors before a part is even cut. During cutting, valuable information is available in real time from tool wear monitoring and cycle times to loads on the spindle - all easily collected into a spreadsheet such as Excel - and then can be sent to a coworker's email for further analysis. This includes data collected from the Blum laser tool setter, bar code scanners or other devices and programs integrated through the control, which features 40 GB of hard drive space and full Ethernet connectivity.

To enhance this capability, Caron Engineering developed an adaptive control application to monitor coolant flow and pressure for this application. The company provides software and engineering products to enhance controls for top CNC manufacturers and manufacturing clients. Working directly with ChipBLASTER and Okuma, National Sales Manager Mark Munroe, explains the next step in the process.

"Add the data collection features of their System Tool Monitoring Adaptive Control (TMAC) product, and the user will now be able to look at historical data to determine tool wear issues. For example, an operator can compare what the coolant pressure and flow levels were when a tool started to draw excessive horsepower and then determine if they are affecting tool wear. Adjustments can then be made to correct tool wear issues as needed."

As a tool's cutting edges deteriorate, Caron Engineering found that horsepower would automatically increase and cause potential problems. The TMAC software now accurately measures and displays true motor horsepower for spindle and/or feed axes, determines when a tool is worn or broken, and directs the machine control to take corrective action before damage can occur to parts and tools. The program protects the CNC machine while providing valuable information about the cutting process, reducing high costs of replacement tooling, lost production and rejected parts by effectively measuring tool wear in real time.

Equipped with new technology and an open mind, the customer was able to enhance their existing equipment with products and applications that cut costs, improved efficiencies and delivered quality results to their customers without any special integration software or additional interfacing hardware.

Making the most of the newest technologies available through an open architecture control and using best practices, creativity and partnerships with experts in the industry can open opportunities that will keep your business viable in an ever-changing market.

Key, Jolyn (2008). Four collaborate to produce die & mold high-speed success. Tooling & Production, 74 (3), 40-41.

For a small Michigan job shop, a technology change provided productivity gains while achieving comparable quality when making prototype and production injection molds.

Granby Mold Inc., Walled Lake Mich., has been building injection molds for automotive and nonautomotive applications since the 1970s. One niche market is molds for automotive chrome-plated emblem components, and the company has created a handful of molds for Lincoln ornaments of various sizes.

After some lean times in the auto market, Granby Mold decided it was time to upgrade its capabilities and diversify its opportunities. The moldmaker hadn't purchased any new CNC equipment since the 1990s, and John Turcotte, Granby Mold's owner and president, felt the company could not excel in this industry without upping productivity. The result was the purchase of an Okuma MB-56V VMC with THINC-OSP (the intelligent numerical control-Okuma sampling path) control. (Okuma America Corp. is based in Charlotte, N.C.)

"Before the MB-56V, we made an electrode to burn the whole cavity of the Lincoln ornament mold," said Turcotte. "We did that to achieve the fine detail required and found it was not even worth going in there with the CNC mills we had been using. However, after getting the new high-speed machining center and seeing the incredible results on other molds, we decided to cut the entire cavity and core without any EDMing."

Eliminating EDMing saved time while achieving high-quality output. The company's polisher noted that the core did not need polishing, but it was easier to polish the milled cavity to a mirror finish than the EDMed one.

Made from P-20 steel, the ornamental mold was cut with a 1mm ballnose endmill at 15,000 rpm with step-overs as small as 0.0003" on finish passes. According to Turcotte, machine tool distributor Gosiger 3D, Plymouth, Mich., gave invaluable support in recommending endmills, speeds, feeds, and programming and tool measurement techniques. "One of the difficulties in machining cavities is to blend corners that are cut using multiple-sized endmills," he said. "Gosiger 3D taught our employees how to utilize a Blum laser to achieve higher accuracy and near perfect cutter-to-cutter blends."

The laser-based measuring equipment was programmed to automatically set the correct tool length, check for any cutter wear or damage and alert the machine and operator of potential problems with a cutter before changing to the next needed one. "We start with a big cutter (4mm) and work down to the smallest size (.02") we need," Turcotte said. "The cutters have to be pretty small to achieve the amount of fine detail in an ornament cavity. We also achieve the same results in hard steels. We recently hard milled two 50- to 52-HRC stainless steel molds and three 48- to 52-HRC S-7 steel molds with great results."

In the case of the Lincoln ornament mold, the cavity and core took approximately 12 hours to machine. The .02" cutter machined about 15% of that time, and did the work that used to be done with EDM. If EDM were used instead, electrodes would have taken at least 12 hours to machine, and 3 more hours to perform the actual burn.

After cutting the cavity and core details, the operator removes the workpieces and checks the spot, which is the fit of the two sides-cavity to core. No spotting work was required on the Lincoln mold.

Paramount to Granby Mold's team was the reliability of the THINC-OSP controller. "We don't have the luxury of testing our programs," Turcotte said. "We just download them into the control, start cutting, turn off the lights and go home. Machining hundreds of details over the past 2 years, we use lights-out machining to compete. The control always does what we program it to do."

Besides satisfying the customer, Granby Mold reduced its costs by about 30 percent by switching from EDMing to high-speed machining.

In addition to automotive molds, Granby Mold designs and manufactures thermoform tooling, rubber molds, stamping die details, and thermoset injection, transfer and compression molds. Employing the VMC opened new opportunities by adding hard milling, prototype mock-up capability, special fixture work and new product design and development to the repertoire of Turcotte's five-man team. He added, "We've built some challenging tools for some pretty tough customers who were really impressed with the difference in the quality of the final work we can now produce."

Caption: Lincoln Ornament

Captions: John Turcotte, owner and president of Granby Mold shop's Okuma MB-56V

Two keys to Busche's success are versatility and speed. Rather than dedicated equipment, the shop uses flexible machining centers and constantly reconfigures them into new cells for new jobs. The speed at which it can do this, in addition to in-house tombstone manufacturing capability, provides the nimbleness to quickly respond to its customers' needs.

Machine tools don't sit idle for very long at Busche. For that matter, they might not stay located in the same spot or even the same company building once a job has ended.

Busche (pronounced with a long "e") has a total of 220 CNC machines in six production facilities in and around Albion, Indiana. Horizontal machining centers (HMCs) represent the largest portion of that capital. The company currently has 97 HMCs, the vast majority of which are from Okuma (Charlotte, North Carolina).

The privately held company primarily performs mid- to high-volume machining work for the automotive and construction industries. Nick Busche, company president, admits that dedicated equipment would likely complete some jobs quicker than his machining centers. However, he believes the flexibility those machining centers offer to perform a wider variety of work is more important than faster production. To that end, the company has become adroit in reorganizing machines into new cells as existing jobs reach end-of-life and new ones begin. That's also why the shop, which runs 24/7 with 450 employees, has yet to justify the use of machine-tending robots. It has found that well-trained personnel, like machine tools, are easier to redeploy.

This strategy is paying off. Busche was a $6.5 million company in 1999. Its projected sales for 2007 are $54 million. Flexibility, speed and in-house resources such as tooling, training and machine service have contributed greatly to this success.

Growing steadily

Mr Busche created his company in 1998. Over the years, the company has formed relationships with select forgers and die casters such that 90 percent of its work is purely value-added machining. That shields the company from absorbing the hit of rising material costs. Automotive work represents 50 percent of its business, down from 70 percent in years past. Except for his first few years in business, Mr. Busche hasn't dedicated more than 15 percent of capacity to any one customer.

In 1999, Mr. Busche merged his business with his brother Jerry's tooling company, which became the Busche Workholding division. That division specializes in designing and manufacturing hydraulic tombstones. Having in-house tombstone manufacturing capability for the company's HMCs allows it to ramp up for new jobs in short order. Mr. Busche says tombstones have been designed and delivered in as little as 3 weeks, versus the 12- to 16-week lead time that's typical when using an outside tooling vendor. This helps the company reach full production levels on new jobs in as little as 6 to 8 weeks. The Busche Workholding division also supplies tombstones to outside shops. In fact, that outside work represents 80 percent of the division's business.

The company also has in-house machine service. Gosiger Inc., Busche's machine tool distributor, maintains a two-person office on-site at Busche. With ever-shrinking delivery schedules, same-day machine service is crucial. If a machine is not making chips, it's not making money.

Cells And Communication

Busche continually adds and/or reconfigures existing machine tools into new cells that are temporarily dedicated to a new job. Busche performs all the project management to determine an effective layout and power requirements. It then hires electricians to put in new drops and riggers to move machines into position. Gosiger technicians assist in leveling and other final installation duties.

Each machining cell is set up with all gaging and other necessary equipment for a particular job. Oftentimes the cells include value-added operations, such as pressure testing for rack and pinion housings, bearing installation, assembly, parts washing and so on. Some cells even include a CMM housed in a compact, air-conditioned enclosure. The company, which is registered ISO/TS 16949:2002, has a total of 14 CMMs.

All parts are traceable back to the machine operator, and the company demands accountability for all parts it ships. For example, if a bad part is returned from a job that required 100-percent inspection, then that operator could be terminated. The company looks at that as an act of insubordination. That's why it provides to cell operators all information needed for a particular job. Currently, part prints, work instructions and other data are provided in the form of laminated printouts.

However, this paper-based medium is being phased out. The company is starting to add 50-inch, touchscreen monitors in each cell, offering access to all job data in a large, digital format. Because revised job information can be quickly uploaded to a job file, operators-and Busche customers-are assured that the most current data is being provided. Although the company is in the initial stages of adding these cell monitors, it eventually will have approximately 100 such touchscreens.

Communication works both ways, however. Each plant has a dry-erase board where employees can list and date specific problems they experience. Such a visual tool spurs corrective action by making all company employees from owners to operators aware of issues that have been identified.

Central Store

Originally, each Busche plant had its own tool crib. On the surface, this might make sense because the facilities are in spread out in different locations. However, maintaining separate tool cribs made tool inventory and usage difficult to track. To eliminate waste and offer better control over tooling and other shop supplies, the individual tool cribs were removed from the facilities and consolidated into one central store serving all plants.

Each plant now includes a compact ToolBoss tool crib/inventory management system from Kennametal (Latrobe, Pennsylvania). Operators must input a part number from a job tool list and scan an identification card before a tool can be pulled. Collected at the central store, this data can be used to create various types of usage and cost reports. Such complete documentation means correct tool inventory numbers are maintained.

All damaged tools are also collected at the store. And each day, managers perform a tool review after their normal production meeting to identify and diagnose repeating tool problems. In addition, the store includes a grinding machine for tool resharpening.

In-House Education

In the summer of 2004, Busche launched plants 6 and 7 (plant 7 is dedicated to turning work). To support those plants, it had to hire approximately 245 people in a span of just 45 days. Training such a large number of employees in such a short amount of time was no walk in the park. Realizing further expansion was likely coming, and not wanting to go through that situation again, the company decided to create its own metalworking training facility. Busche's educational center, located away from its main Albion campus, went live in 2005.

The facility includes a number of computer workstations running shop training software from MasterTask Training Systems (Rockford, Illinois). Busche uses three MasterTask training modules-measurement, CNC lathes and machining centers-which require 10, 22 and 25 hours of study, respectively. Employees often schedule time to train before or after their work shift. Because the classes are held off site, there is less chance for workplace distraction. To date, 105 employees have successfully completed all three training modules, and the vast majority has stayed with the company.

The educational facility also houses a CMM, a granite table with gaging equipment and an AV-equipped meeting room. Mr. Busche says the investment to create and maintain this resource is small relative to the payback. Plus, the educational facility serves as a good sales tool for potential customers. Mr. Busche says his customers want to form long-term partnerships with machine shops. Such an investment in training demonstrates that the company is not only committed to success, but is in it for the long haul as well.

Preparing For Future Growth

Mr. Busche wants his company to be one of the major players in value-adding machining. That means more expansion is on the horizon. Some Busche customers are asking the company to locate closer to their production facilities. Mr. Busche would prefer to acquire existing shops near his customers and integrate his company's philosophies into the new division. The goal is to grow Busche to become a $250 to $300 million business.

He says the work is out there.

Most of the research center's parts are wind tunnel model components produced for the aerospace exploration program - rocket-type models in preparation for the changeover from the shuttle to rocket program. The data from the models will be gathered and compared with a variety of calculations. "They are long bodies of revolution with complex milling features and requiring five-axis work such as drilling obscure angled holes," explains Deputy Product Manager, Jeff Brady. "A lot of what we do is completing what we call 'door-knob shapes' with all sorts of different contours."

Because of the extensive design time and frequent requirement changes for their part needs, the average project takes approximately a year to complete, yet Brady's team may only have up to two months to make the hardware. With parts ranging from 2 to 14 inches in diameter and 4 to 60 inches long, some parts are produced in different stages and assembled or connected to make a scale model for exploration and testing purposes.

A lot of time had been spent moving between lathes and milling machines several times to meet their part requirements. Upgrading to the new Okuma Multus B400, now practically all of the set-ups can be performed on the one machine, reducing a lot of set-up time and making it easier to meet tight delivery schedules.

The first rather complex piece was a model support structure that will support the model in the wind tunnel. It took four weeks to produce, and resembles a cone or funnel - approximately 3-12 inches in diameter and 20 inches long. A lot of turning was required for the primary cone shape followed by milling of the pockets and then cutting out the interior of the part. Next, a diamond-shaped slot was cut on the back end, and putting some precision holes into the structure. The last set-up was for precision-type lapped holes to mate with some balance sleeves.

The piece was so big conventionally, it would have been manually rotated several different times, either 180 degrees, 90 degrees, then to put holes into it, rotate it at 30 degree intervals, etc. "Not having to orient and make multiple setups saved us an incredible amount of time," explained Brady. "It was a very good test-part for the machine - to see the machine's capability and that piece would probably would have taken six or seven set-ups on a conventional machine and we did it all within two set-ups."

The part took four weeks to complete because the new post was also being resolved during this time. However, Brady believes that time will be reduced by about 25% once the operator learns all of the bells and whistles of the Multus, its "B" and "Y" axis, plus it's new THINC-OSP control. "Advancing to the Multus from the older/simpler technology left a lot to learn and adapt to, the technician has had to catch up a bit."

To develop the new Okuma Multus post, NASA technician Dave Fahringer worked closely with TriMech Manufacturing Inc.'s Applications Engineer, Chris Cole, to best utilize their FeatureCAM product with Okuma's THINC-OSP control. Because each project is completely different with new features, new programming strategies are always required. Machine alarm conditions would put a stop to the work if the code was not in order. "After considerable tweaking, we seem to have it nailed now," said Fahringer. "TriMech really stuck with me to get the post right, and I am very thankful for that!"

FeatureCAM allows a programmer to draw or import a part, identify the part components such as holes and surface milling, and in many cases, simply click the simulation to generate the necessary NC code. The program automatically selects tools, calculates feeds, speeds, stepovers, depth of cut, determines roughing and finishing operations and generates toolpaths and NC code flawlessly. The post processor library has many posts and the programmer/operator can adapt, rename and edit those to create custom posts.

The Okuma THINC-OSP control is a true PC-based, open architecture platform that uses standard G- and M-codes. With a 40 GB hard drive, the control can accept practically any third-party Windows-based software. "The touch screen is much larger on the new control and being Windows-friendly helps the operator," said Brady. "He is able to make the edits or other quick-changes easily on the machine or by importing programs to the control through the Ethernet."

Another technological upgrade was the tool availability on the new multi-tasking machine. Whereas the old machines had a turret with twelve spaces, the operator could only use about six tools in order to avoid interference with the job or the chuck. "We use about 15-20 tools in it for the current job and we can now spread them out through 40 tool slots," explains Brady. "We use small drills, larger drill chucks, different turning and facing tools and the holder is set up to cover just about anything that may come in. That way we don't have remove the tool from the turret, clean it up and then re-insert another tool."

Using mostly aluminum, the NASA group is getting heavy into the steels - 13-8 Stainless Steel and Vascomax steel - a very hard, "nasty" steel, according to Brady. "It slows the process down - you can't rush the process, but it is durable for what we are doing," he said.

"It's a different approach here [at NASA Langley Research Center] than out in the business world where you are trying to make money and utilize every inch of the machine to make the part from five minutes to two minutes," said Brady. "If we had 100 parts to do and they were all the same, then we'd make the time to look into streamlining the operation further. We don't put a lot of emphasis on that here, but we do try to be more efficient in order to meet our compressed schedules and get more jobs out in a timely manner. With new machines and new technology, we can do that."

With approximately 90% of the wind tunnel models being applied to future aerospace projects, Brady's team will have a good chance of seeing their hard work applied to the space exploration in approximately 3 to 10 years.

Although on race days it's all about the teams, sponsors and drivers, many forget that behind the scenes is where a lot of action takes place. Okuma Corporation, a sponsor of RCR since 2001, is the "Official Machine Tool" for RCR. Okuma, a leader in machine tools for over 108 years, is the partner and supplier of CNC lathes, machining centers and grinders that are manufacturing over 300 unique engine parts for the 500 engines RCR will produce this year.

"We supply a majority of the components to the engine shop," said RCR Manufacturing Manager Rick Grimes. "Every cylinder head that goes through this building, every water pump pulley, alternator/crank pulley, alternator bracket, the motor plate, and lifter - are all either manufactured or configured (in the case of a cylinder head) on Okuma machines at our facility."

You'll find the Okuma logo on the left back tail light of the RCR Cup cars, and on the C post of its Busch cars. You'll also find a multitude of Okuma Computer Numeric Control (CNC) machines at the on-site Okuma Technology Center that meet the growing needs and responsibilities of the RCR cars and partnerships - including engine building collaborations with Dale Earnhardt Incorporated (DEI).

"We couldn't be where we are today in this industry without Okuma equipment," continues Grimes. "It's a partnership that goes both ways: Okuma supplies the equipment, the application engineering support, and the technical support that we need, and we help them grow the Motorsports side of their business."

When this partnership began in 2001, RCR recognized the need to control their cam shaft destiny. Interestingly, it was RCR that introduced COMP Cams, the leading camshaft manufacturing for high performance racing components, to Okuma shortly after the partnership began. And it was COMP Cams that was instrumental in helping to develop the next generation CAM Grinder (GC-34NH) and continues to use Okuma lathes and grinders on their shop floor every day. When RCR spoke with Comp Cams, the choice for product was simple&use the best! RCR became the first NASCAR team to own a dedicated cam grinder. Not only can they turn out a camshaft from cam core to finished product and test within four hours, but finished cams off the grinder are put directly into the Cup, Busch and Truck Series engines that have produced more than 60 victories since 2001.

With the release of The Intelligent Numerical Control (THINC), Okuma has taken technology to the next level and beyond with plug and play capabilities and an infinite number of possible programming solutions. Add more than 30 partners from Partners in THINC, from Renishaw and Marposs to Sandvik and Zeiss, and you have a one-stop facility for securing multiple solutions - all from one physical location in Charlotte, North Carolina.

With the THINC-OSP control at the center of all solutions, RCR is considering a variety of options including a completely paperless process utilizing the ToolBoss and Zoller Tool Management System, automating the facility with ABB or FANUC robotics, and/or incorporating Midaco pallet changers and balluff chip IDs. "The things that I see down there [at the Partners in THINC facility] can benefit us at RCR," said Grimes. "The technology of the THINC control is limitless now with the PC-based control. We need this technology to keep us at the top of our game."

There's no better example than the spring race at Richmond International Raceway in 2003. The difference between 1st and 36th place on the starting grid was 0.387 seconds. "That's why that operation is here - to gain that 1/10th of a second. It's all about the performance on the race track. If we don't continue to improve, we can't improve on the race track."

According to Grimes, the new Okuma machines with the THINC control will allow them to adapt to changing technologies faster and more efficiently. "We need to have equipment to handle what we can do with the Car of Tomorrow. By having all of this equipment in house, it allows us to do more things internally - and confidentially - in order to give us a more competitive edge on the race track."

Technology is at the heart of the RCR and Okuma Partnership, and Grimes considers Okuma number one in the machine tool industry. "They are the forerunner in the market of machine tools and continue to improve with their new PC-based control (THINC). Everyone was in shock and awe at IMTS 2004 when both the cylinder head manufacturing process and the THINC control was revealed. Okuma keeps us current in technology to help us implement new methods of machining that will allow us to make parts we've never been able to make before."

"RCR continues to need to keep that confidentiality and to have the competitive edge&that's why Okuma is here. We have to have the competitive edge to win races, to win championships to take care of our sponsors and to keep our drivers happy. When they win, we eat!"

RCR is on the fast track to upgrading its shop in order to win more races, not only through their partnership with Okuma, but now with Partners in THINC. "The value of Partners in THINC is that it's a one-stop store now&.not only a store, but where you can actually touch, feel, smell, and look at end results," said Grimes. "You can give them your parts and drawings and say 'make this for me - show me how it's going to work on my stuff.' As a result, we saw our water pump pulley being made on the Multus with an ABB robot. The LNS barfeeder was running our caliper mount studs. That's pretty impressive to see your parts being made when you walk through someone else's doors."

As a result, some of what RCR has seen at Partners in THINC may change its strategies regarding technology in the future. The partnership with Okuma will continue in order to keep up with the multiple engines and teams they provide for each week. It will also help keep its drivers' dreams alive for the NASCAR NEXTEL Cup Race to the Chase and the ultimate prize of winning a championship.

"For us to be number one in this industry, we have to have the support from the number one people around the world. Our partnership and possibilities with Okuma are second to none."

ATS Systems has been supplying accessory solutions such as collet chucks, quick-change chucks, rotary tables, and barfeeders on Okuma machines for more than 20 years and was identified by Okuma America Corporation as a partner having unusual product breadth, making closer cooperation sensible. As a Partner in THINC, ATS Systems will keep an office and regularly interact with Okuma's engineers at the Partners in THINC facility in Charlotte, NC. There, the two firms can test innovative ideas and sharpen solutions in a real-world setting. Darren Castoria, Regional Sales Manager for ATS Systems summarizes: "Becoming a Partner in THINC will strengthen our excellent relationships with Okuma and its dealers, and it will allow all parties involved to provide superior metal cutting solutions to the industry."

Okuma is a world leader in machine tool technology with a longstanding and strong presence in North America. Okuma's THINC control is a 40 GB, PC based control with open architecture that, among other benefits, permits peripheral items such as machine tool accessories to have plug and play compatibility.

For more information on Okuma, Partners in THINC or ATS Systems, you can visit www.okuma.com, www.partnersinthinc.com or visit www.ats-s.com.

"Our success with Bill Miller Engineering, Don Schumacher Racing, Richard Childress Racing and Competition Cams have helped certainly helped us show Don Prudhomme that we are interested in helping the Snake Racing Team both on and off the track," said Okuma America Corporation President and COO, Larry Schwartz. "It's an opportunity to become an associate sponsor with another world-class organization and continue the momentum we have providing quality CNC machine tools to the high performance racing industry."

After realizing their first win in only the second race of the 2008 POWERade Drag Racing Series season, Okuma couldn't be more pleased with the partnership agreement. Larry Dixon drove The U.S. Smokeless Tobacco Company/Okuma top fuel dragster to victory lane at the Checker Schuck's Kragen NHRA Nationals at the Firebird International Raceway in Phoenix on February 24, 2008, only one week after unveiling the new car and sponsorship in Pomona, California.

"We are very pleased to begin a new, successful relationship with everyone at Okuma," said Prudhomme. "Our team is always striving to find ways that we can improve our performance and Okuma is helping us realize that goal. We are excited about this new partnership and I look forward to Okuma playing a key role in our success for years to come."

In addition to Okuma machines being used in the Don Prudhomme Racing shop in Brownsburg, Ind., Okuma identification will appear on all Don Prudhomme Racing race vehicles, transporters and team shirts.

For more information on Okuma or Don Prudhomme Racing, please visit www.okuma.com or www.snakeracing.com.

Caption: Don "The Snake" Prudhomme with Okuma representatives, Ted Driggs, Seth Machlus and Mindy Mikami and Snake Racing driver, Larry Dixon

Okuma America Corporation is the U.S.-based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology. Under the terms of the agreement Okuma and regional distributor Morris South will provide equipment and support services for the automotive engineering research and graduate education programs in the Carroll A. Campbell Jr. Graduate Engineering Center (CGEC), the academic anchor for CU-ICAR. In addition, Okuma will provide an annual internship with the company for a student enrolled in the automotive engineering graduate program.

CGEC Director Tom Kurfess announced the first Okuma intern, Chan Wong, has already begun working in the company's U.S. headquarters in Charlotte, North Carolina. He noted that with locations throughout the world, Okuma offers students outstanding internship opportunities.

Instead of donating specific equipment, Okuma is providing state-of-the-art equipment in a consignment agreement that will continuously upgrade equipment for new versions as improvements are made. The arrangement also enables the CU-ICAR team to effectively tailor their capabilities to meet industry needs by working with Okuma to identify and provide the best possible equipment for newly initiated research and education projects.

"Okuma is committed to making sure our students and faculty have access to the latest technology," Kurfess said. "They have allowed us to avoid obsolescence, one of the biggest problems we face in terms of equipment. We do not have to dispose of or replace equipment; they will update as new generations of this machinery become available. The assurance that they will be working on the latest equipment from one of the world's most outstanding machine tool companies is extremely important for our current and potential students, and it is also important for those who will be hiring our graduates. We are very grateful for the very generous terms of this agreement."

The Okuma equipment will be used in both research and education programs, according to Kurfess. Research applications will include machining, metrology and machine integration research projects, as well as serving as available resources for developing new proposals. The equipment will be integrated directly with graduate engineering classes such as automotive manufacturing processes, production preparation and launch, and industrial automation. Faculty will use the equipment to provide demonstrations and data to reinforce class concepts.

After spending many years in the automotive industry Bob Kral, Vice President of Operations for Okuma America Corporation, sees extensive value in automotive industry research. "As a car guy, I know how important it is to find those new innovations that break through the technological barriers we are particularly facing now in the domestic market. Okuma appreciates the opportunity to be a part of a premier, global initiative that supports research for advanced manufacturing, and promotes higher learning."

Kurfess said the partnership with Okuma and Morris South will improve the automotive engineering graduate program significantly by providing practical reinforcement of modeling and control concepts. "It improves our capabilities to enable research in advanced machining and machining control areas, which is critical to automotive manufacturing. Through the expert support the companies will provide, students will also interact with some of the machine tool industry's top control system developers. Additionally, domestic and international internships are a critical part of our graduate program, and this partnership offers our students tremendous opportunity. We look forward to working with these outstanding companies."

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