Jou nal o Technology and Exploi a ion ISSN 2451-148X
in Mechanical Enginee ing A ailable online a :
Vol. 4, no. 1, pp. 10–28, 2018 h p://j eme.pl
Resea ch a icle
10
© Au ho Sándo Bodzás, Béla K akkó, Published by Polish Associa ion o Knowledge P omo ion, 2018
This is an Open Access a icle dis ibu ed unde he e ms o he C ea i e Commons A ibu ion License (CC-BY 4.0)
(h p://c ea i ecommons.o g/licenses/by/4.0)
LEAN MANUFACTURING PROCESS PLANNING FOR 5 AXES CNC DRIVEN MILLING
MACHINE
Sándo Bodzás1
✉
, Béla K akkó2
1✉ Uni e si y o Deb ecen, Facul y o Enginee ing, Depa men o Mechanical Enginee ing, 4028 Deb ecen
Ó eme ő s . 2-4., email: bod[email p o ec ed]eb.hu
2 Indus ial Enginee
Submi ed: 2017-12-14 / Accep ed: 2018-03-19 / Published: 2018-03-29
ABSTRACT
The aim o his publica ion is o de e mine he OEE (O e all Equipmen E iciency) indica o o 5 axes milling
machine ound a Diehl Ai cabin Hunga y L d. o he p esen and u u e s a e. Based on his alue, he u iliza ion
o he machine o he gi en p oduc ion amoun can be calcula ed. Wi h he op imal choice o he igh
p oduc ion pa ame e s ( he numbe o cu s, eeding, dep h o cu , e c.) g ea e p oduc i i y can be achie ed i.e.
he machine main ime ( ime o cu ing) will be less. The possibili ies o he educ ion o he machine ime will
be analysed and calcula ed. Se ing o he app op ia e echnological pa ame e s he machine main ime could
be dec eased. The calcula ion o he machine main ime will be de e mined o he mos equen manu ac u ing
echnologies.
KEYWORDS: OEE alue, p oduc ion planning, LEAN, milling machine
1. In oduc ion
LEAN is an o ganiza ional company conduc ing sys em which aims o p oduce i s p oduc s and
se ices by he mos economical way. A LEAN company a ge s i s ac i i ies on he cus ome s’ needs,
and wha hey pe cei e as aluable. Those hings which a e no o alue o he cus ome , and o
which hey a e no willing o pay, LEAN sys em akes as loss, and inc eases he e iciency o he
p ocesses by ceasing hese losses o educing hem o he maximum [4], [5].
a) Ai bus A320 ype Single Aisle b) A330/340 ype Long Range
Fig. 1 Ai c a ypes
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
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Nomencla u e
A A ailabili y indica o
P Pe o mance indica o
Q Quali y indica o
OEE O e all Equipmen E iciency
so n [min] no m ime o he o al p oduc ion se ies
e [min] p epa a ion and inishing ime
da [min] base ime
[min] machine main ime
m [min] supplemen a y ime
k [min] ime o suppo ing p oduc ion
p [min] ime o es and na u al needs
n [1/min] numbe o e olu ion
[mm] eed
z [mm] eed o one edge
d [mm] diame e o he ool
L [mm] p e- a el
L [mm] o e a el
L [mm] leng h o he wo kpiece
Lm [mm] leng h o manu ac u ing
i numbe o cu
κ [°] ool cu ing edge angle
bw [mm] wid h o he wo kpiece
φ1, φ2 [°] angles o w ap
a [mm] dep h o cu
T [min] machine main ime o he o al
manu ac u ing
kc, k , kp [N/mm2] speci ic cu ing o ce
h [mm] chip hickness
b [mm] chip wid h
Pc [kW, W] cu ing powe
c [mm/s] cu ing speed
[mm/s] eed speed
Fc [N] majo cu ing o ce
zs numbe o cu ing edges
ψ swi ching numbe
Diehl Ai cabin Hunga y L d. (9. Ipa i s ee , Nyí bá o ) is he i s and only subsidia y o Diehl Ai cabin
GMbh loca ed in Laupheim, and h ough i s pa en company, his company is a membe o he Diehl
Ae oSys ems. In Nyí bá o , he e a e mo e han 400 labou e s wo king o he company. The aim is o
ha e 550 labou e s un il 2018.
A Diehl Ai cabin Hunga y L d. doo s – doo ames, side elemen s, clima ic ubes o Single Aisle (sho -
e m a el) and Long Range (long- e m a el) ai plane ypes a e p oduced (Figu e 1). O he p oduc s
a e isola ion packages o Ai bus ai c a s
2. Maka ype CNC d i en milling machine ha ing 5 axes
A Diehl Ai cabin Hunga y L d. he e is a MAKA M7 ype CNC d i en milling machine ha ing 5 axes
(Figu e 2). The o e all dimension o he machine: 5.2 m x 9.2 m x 6.2 m. Yea o i s p oduc ion: 2015.
Fig. 2 MAKA M7 ype CNC d i en milling machine [1]
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
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Fig. 3 Main spindle and he ool s o age wi h 12 ool places
The milling machine has 2 wo k ables. Because o his, manu ac u ing ac i i y and he ixing o he
wo kpiece can be pa alleled (Figu e 2) [1]. I we would like o use mo e han one ool, he au oma ic
ool change sys em can change ool and i is possible o ix 12 ools in he ool s o age sys em. (Figu e
3) [1], [2].
3. The calcula ion o OEE indica o
The OEE (O e all Equipmen E iciency) alue shows pe cen age o he amoun o he p oduc s
a e p oduced, o which he machine is being capable unde op imal ci cums ances [4], [5] (Figu e 4).
OEE indica o is o med by 3 ac o s [5]:
 The indica o o a ailabili y (A) e e s o hose ime losses when he equipmen could
p oduce bu due o some easons i does no wo k. The losses ha in luence his ac o :
mal unc ion, change o e ime, and he ime o ool change.
 Pe o mance indica o (P) includes hose losses when he machine is ope a ing bu i is no
p oducing a all o no p oducing wi h he app op ia e amoun . The sou ces o losses, which
in luence his ac o : mic o shu downs, loss o speed.
 Quali y indica o (Q): he equipmen is unning, p oducing bu he p oduc canno be used
because i s quali y is no app op ia e. The sou ces o losses, which in luence his ac o :
quali y loss, s a up loss.
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Fig. 4 The backg ound p inciple o he calcula ion o he OEE
A Diehl Ai cabin Hunga y L d. OEE indica o is calcula ed annually o MAKA ype CNC milling machine.
Sidewalls, doo s and doo ames a e he p oduc s p oduced by his machine [1]. Fo calcula ion he
ollowing da a a e needed:
 numbe o p oduced pieces;
 ime schedule;
 numbe o ewo ked wo kpieces;
 numbe o sc aps;
 p oduc ion ime;
 unplanned shu downs.
The o al amoun is he numbe o he o al p oduced pieces in he examined pe iod.
The s eps o calcula ion o OEE indica o a e he ollowing [4], [5]:
To al amoun = numbe o p oduced pieces + numbe o ewo ked pieces+
+ numbe o sc aps (1)
Indica o o a ailabili y (A) = (P oduc ion ime – Unplanned shu downs) / P oduc ion ime
(2)
Pe o mance indica o (P)= (To al amoun x Time schedule) / P oduc ion ime
(3)
Quali y indica o (Q) = Numbe o p oduced pieces / To al amoun
(4)
QPAOEE 
(5)
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
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Fo 2015 (cu en s a e o a ai s) based on da a a ailable and using he o mulas in (1) – (5) he alue
o OEE indica o has been calcula ed, which equals 47%. So i.e. MAKA ype CNC milling machine
p oduces 47% o i s numbe o p oduc s, o which i would be capable in op imal case [1].
Fo 2016 ( u u e s a e) a Diehl Ai cabin Hunga y L d., cus ome s’ needs, numbe o p oduced p oduc s
and hei complexi y a e con inuously g owing. Based on da a a ailable and using he o mulas in (1)
– (5) he alue o OEE indica o has been calcula ed, which is 159.3 %. The calcula ed OEE indica o is
abo e 100%, which means i he e is ha high p oduc ion olume, one MAKA ype CNC milling machine
will no be su icien o p oduc ion. Thus, o his eason 2 machines will be indispensable.
4. Making a compu e p og am o OEE indica o calcula o
Fo e icien calcula ion o OEE indica o , we ha e made a compu e p og am in MATLAB
de elope en i onmen . The aim was o ease he wo k o he company as wi h he help o he p og am
OEE indica o s can be calcula ed no only annually bu also mon hly. Inpu da a o he p og am a e he
ollowing [1], which should be p o ided:
1. Fo how many mon hs o yea s calcula ion would be made
2. Fo which mon h o yea s calcula ion should be made
3. The numbe o p oduced i ems
4. Time schedule exp essed in minu es
5. Numbe o ewo ked p oduc s
6. Numbe o sc aps
7. P oduc ion ime exp essed in minu es
8. Unplanned shu downs exp essed in minu es
A e all, he p og am calcula es he ollowing alues below, shows hem on he sc een and sa es in
a di e en ile [1]:
 To al quan i y;
 A ailabili y indica o ;
 Pe o mance indica o ;
 Quali y indica o ;
 OEE indica o ;
 OEE indica o in %;
 Numbe o machines needed o p oduc ion.
The p og am d aws 8 unc ions, which a e he ollowing (Figu e 5) [1]:
 Mon h o yea – Numbe o p oduced pieces;
 Mon h o yea – Time schedule;
 Mon h o yea – Numbe o ewo ked pieces;
 Mon h o yea - Numbe o sc aps;
 Mon h o yea – P oduc ion ime;
 Mon h o yea – Unplanned shu downs;
 Mon h o yea – To al quan i y;
 Mon h o yea - OEE indica o diag am.

Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
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Fig. 5 Ou pu unc ions o he compu e p og am
5. De ining he p oduc ion main ime
Possible main p oduc ion ope a ions a e de ined on he machine (d illing, milling) and hei main
machine ime, in gene al, in ela ion o he echnological pa ame e s. Figu e 6 shows he s uc u e o
no m ime o o al p oduc ion se ies.
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
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Fig. 6 The s uc u e o no m ime o he o al p oduc ion se ies
The machine main ime ( ) is a pa o he base ime du ing which he shaping occu s di ec ly on he
wo kpiece.
The supplemen a y ime ( m) is a pa o he base ime which is only indi ec ly necessa y o he
comple ion o he manu ac u ing ask. I is epea ed on e e y wo kpiece. Fo example, wo kplace
clamping.
The mos gene al equa ion o he ime o p oducing one i em (Figu e 6) [3], [7], [8], [9], [10], [11]:
pkm d 
(6)
De ining he du a ion o he ope a ion elemen s [3], [7], [8], [9], [10], [11]:
g
L
i
n
L
i 


(7)
5.1. De e mina ion o he machine main ime in case o u ning
The u ning is con inuous cu ing wi h ci cle shaped chip and a bi a y eed mo ion which is
pe pendicula o he cu ing di ec ion. I s ool is la he machine (Figu e 7). The isola ed chip is usually
cons an sec ional. The cu ing o his is occu ing con inuously [3], [8], [12], [13], [14].
No m ime o he o al
p oduc ion se ies, so n
P epa a ion and
inishing ime, e
Time pe pice o n pieces o
wo kpiece, 𝑛 ∙ 𝑡𝑑
Base ime, da
Machine main
ime,
Supplemen a y
ime, m
Addi ional ime
Time o suppo ing
p oduc ion, k
Time o es and
na u al needs, p
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
17
Fig. 7 The heo em o u ning echnology
The speci ic cu ing o ce is w i en o he h ee o ce componen s (Figu e 7) [3], [7], [12], [13]:
(8)
The e i o y o he chip sec ion (Figu e 7) [3], [7], [12], [13]:
(9)
whe e
(10)
(11)
The o mula o he cu ing powe is
(12)
In Figu e 8 a h ead cu ing manu ac u ing p ocess could be an example. The numbe s (1 -6) a e
nomina ed as he manu ac u ing s eps. The aim is o calcula e he o al machine ime. The machine
imes o e e y manu ac u ing s eps mus be added.
n
OD1
OD2
a
F
Fp
Ac
n
Fc
Fp

cpp
c
ccc
AkF
AkF
AkF



hb aA pc 
p
a
b
h


sin
sin


ccc FP 
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
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Fig. 8 De e mina ion o he machine ime in case o h ead cu ing
The o al machine ime is
(8)
The ime o he h ead cu ing manu ac u ing s ep depends on he h ead cu ing s a egy (Figu e 9).
a) adial o symme ical b) one sided c) wo sided o edge changing
Fig. 9 Designing o cu ing p ocesses in case o h ead cu ing echnology [14]
In case o adial o symme ical h ead cu ing p ocess (Figu e 9.a) he wo cu ing edges o he cu ing
ool a e loaded equally. The machine main ime will be long.
In case o one sided h ead cu ing p ocess (Figu e 9.b) only one cu ing edge is loaded ha is why his
cu ing edge will be wea ing. The machine main ime will be lowe han he adial o symme ical
p ocess.
In case o wo-sided h ead cu ing p ocess (Figu e 9.c) wo cu ing edges a e loaded. The di ec ion o
he cu ing ool always changes.
n
OD
1
2
3
4
5
6
66
6
55
5
44
4
33
3
22
2
11
1
g n
L
2
n
L
n
L
n
L
3
n
L
n
L












Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
25
Based on (24), (25) and (26) he o al cu ing o ce is
(27)
The cu ing powe is
(28)
Based on Figu e 17 he leng h o milling is:
(29)
Based on (29) and (7) he machine main ime is:
(30)
Fig. 17 De ining milling leng h o ace milling
6. Calcula ion o machine main ime o manu ac u ing keyway
Figu e 18 shows he echnology o manu ac u ing a keyway. Du ing manu ac u ing in case o e e y
cu he ool goes in o he dep h o he keyway wi h ap alue (i.e. dep h o cu ), hen he ma e ial is
n
d
L
L
Lm
L
bw


 d
z
b akF wzcc
)(
1060 6kW
bak
P wc
c


dLLLL m 
n
dLLL
i
L
iT
m




Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
26
peeled along he leng h o he keyway. Because o hese ac s he e a e 2 componen s ha make up
he main ime o he echnology ( he componen owa ds he di ec ion o he dep h o he cu , he
componen owa ds he di ec ion o eeding).
Fig. 18 Technological planning o keyway manu ac u ing
Based on (7) he main machine ime o one cu is (Figu e 18):
(31)
I i is he numbe o cu s, hen machine main ime o milling o he o al keyway is:
(32)
7. The educ ion o he machine ime
Exis s many me hods o educing o he machine ime. This ime could be educed by using o
in age ool, mo e a ou able cooling and lub ica ion condi ions o educ ion o he li e o a ool.
High educ ion o he machine ime could be eached by he con ac ion o manu ac u ing s eps (Figu e
19 and 20).
1
n
Od
bw
2
n
ap
L
ap
nz
a
nz
dL
z
p
z





i T 
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
27
Fig. 19 Con ac ion o u ning and d illing manu ac u ing s eps
Fig. 20 Con ac ion o u ning manu ac u ing s eps
8. Conclusion
We ha e de e mined he OEE indica o alues o MAKA ype CNC d i en milling machine ha ing
5 axes ound a Diehl Ai cabin Hunga y L d. o he pe iod o 2015 and 2016.
n
n
n
n
Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018
28
The esul s ha e shown ha he u iliza ion o he machine is 47% in 2015. Al hough o making
calcula ion o 2016, we ob ained esul ha 2 CNC milling machines will be necessa y o p oducing
he es ima ed numbe o p oduc s.
We ha e de eloped a compu e p og am o he analysis and calcula ion o he OEE indica o . Wi h
he help o ou compu e p og am, OEE indica o alues o any ypes o machine can be calcula ed
easily and as . This will acili a e he ac i i y o he company.
Machine main ime o he main echnological ope a ions on he milling machine ha e been
de e mined. Du ing p oduc ion o op imise he machine main imes, he igh echnological
pa ame e s ( eeding, dep h o cu , o a ional speed e c.) should be chosen.
Due o hese, a highe numbe o p oduced i ems du ing a gi en pe iod could be ob ained. Based on
machine main imes, no m ime o he o al p oduc ion se ies can be planned.
9. Acknowledgemen
The wo k/publica ion is pa ly suppo ed by he EFOP-3.6.1-16-2016-00022 p ojec . The p ojec
is co- inanced by he Eu opean Union and he Eu opean Social Fund.
10. Re e ences
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