Company-tailored MICRONITE Deployment
Focus on a business model
Job Shop – Manufacturing Cell – High-Volume Machining – Small-Batch Production
Objectives
- Formulate requirements for the company-tailored control system with consideration of equipment, products, and customer request
- Develop standard procedures for diagnostics of machine, tooling, and inspection capabilities
- Establish guidelines for design of cost-efficient control plans tailored to specific products
- Utilize real-time process data for optimization of predictive control models
- Develop company-tailored training courses for operators, engineers, and managers
- Achieve substantial improvements in quality and productivity
- Achieve reduction of labor and time for engineers, managers, and operators
- Create framework for validation of MICRONITE software
Off-site MICRONITE Pre-launch
- Design of product-specific gaging and process control stations
- Remote system installation and testing
- Import of CAD drawings
- Testing of CMM and/or Vision System output using MICRONITE models
- Probing design of control plans by class of characteristic and cutting tools
On-site MICRONITE launch – $110/hr.
In-depth engineering studies
- Development of metrological testing schemes and launch of Measurement Control System
- Data capture and validation of accuracy and precision of measuring devices
- Estimation of permissible tolerances for inspection methods and fixtures
- Metrological tests and certification of operator measurements
- Process & Quality Engineering
- Analysis and quantification of capability of cutting tools to hold tolerance
- Acceptance of process controllability
- Analysis and quantification of measuring capability and form variation for running processes
- Identification of probable causes of scrap and excessive variation
- Analysis and quantification of machine errors
- Product-specific control plan development and assignment of features to cutting tools
On-site training
In two weeks MICRONITE changes the way companies control production and machining processes
MICRONITE administrators, process and quality engineers (classroom)
- Main features of knowledge-based MICRONITE system
- Explanation of selective functions fitted to company equipment and products
- Software navigation and data analysis
- Automation of multi-source data capture
- Automatic certification of product quality and process capability
Operator training (classroom)
Data entry, process views, and process actions
- Customization of interfaces for operator convenience
- Process actions and troubleshooting using MICRONITE control features
- Communication between operators and supervisors
Operator training (shop floor)
- 3-shift hands-on supervision of inspection process and operator actions
- Detailed explanation of visual representations related to machine-and-tool performance
- Emphasis on value of data accuracy providing reduction of inspection and prevention of defects
On-site analysis and optimization of inspection process – $110/hr.
- Analysis of process output with tool-coordinated displays of dimensional features
- Fine-tuning of predictive control models, sampling frequencies, and sample sizes
- Establishment of reliable control plans for zero-defect machining and grinding
Off-site engineering review and roundtables (On-demand Webinars) – No Charge
- Customer support on demand
- Continual reduction of cost of quality
- Re-classification of dimensional characteristics by tool-critical and quality-critical groups for reduction of inspection time
- Optimization of predictive models for reliable scrap prevention
- Continual reduction of production and tooling costs
- Analysis of tool performance and tool life losses
- Data-driven reduction / optimization of cycle time
- Real-time monitoring of production losses
Typical timeline of MICRONITE implementation