Lean Manufacturing Process Planning for 5 Axes CNC Driven Milling Machine

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 11 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 12 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. Jou nal o Technology and Exploi a ion in Mechanical Enginee ing Vol. 4, no. 1, 2018 13 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 14 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 15 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 16 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 18 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 [1] S. Bodzás, Gyá ás e ezés MAKA ípusú CNC ezé lésű 5 engelyes ma ógép e, hesis, LEAN p o ession, Uni e si y o Deb ecen, Deb ecen, p. 67., 2016. [2] M. Be a, CNC sze számgépek sze szám endsze ei, Collage o Nyí egyháza Publishe , Nyí egyháza, p. 155, ISBN 978 615 5545 03 0 [3] I. Dudás, Gépgyá ás echnológia I., A gyá ás echnológia alapjai, 2. edi ion, Műszaki Köny kiadó L d., Budapes , p. 584, ISBN 963-16-4030-2, 2011. [4] N. Má ai, Lean Menedzsmen p esen a ions, Uni e si y o Deb ecen, Deb ecen, 2016. [5] GY. Péczely, CS. Péczely, GY. Péczeli, Lean 3, Te melékenység ejlesz és egységes endsze ben, A. A. S ádium Diagnosz ikai és Menedzsmen L d., Budapes , p. 690, ISBN 978-963-08-3163-5, 2009. [6] L. Wilson, How o implemen Lean Manu ac u ing, Second Edi ion, p. 419, ISBN 978-0-07- 183573-2, 2015. [7] L. Bálin , A o gácsoló megmunkálás e ezése, 2. kiadás, Műszaki Köny kiadó K ., Budapes , p. 883, 1961. [8] F. Klocke, Manu ac u ing P ocesses I, Cu ing, RWTH Edi ion, RWTH Aachen Uni e si y, p. 524, ISBN 978-3-642-11978-1, 2011. [9] J. A. Schey, In oduc ion o Manu ac u ing P ocesses, McG aw – Hill Book Company, p. 392., ISBN 0-07-055274-6, 1977. [10] J. G. B alla, Handbook o Manu ac u ing P ocesses, Fi s Edi ion, Indus ial P ess Inc., New Yo k, 2007, ISBN 0-831 1-3179-9 [11] H. A. Yousse , H. El ho y, Machining Technology, Machine ools and ope a ions, CRC P ess, Uni ed S a es o Ame ika, p. 672, ISBN 978-1-4200-4339-6 [12] L. F id ik, Fo gácsolás I. (Fo gácsoláselméle ), Miskolci Egye emi Kiadó, p. 205., 2011. [13] K. Gyáni, Gépgyá ás echnológia alapjai I., Tanköny kiadó, Budapes , p. 128., 1980. [14] J. Bali, Fo gácsolás, Tanköny kiadó, Budapes , p. 538., 1988.