The challenging installation schedules and time constraints demanded when delivering turnkey projects; the need to quickly bring installed systems to the required levels of production; and the requirement to prove the quality of manufactured parts: All these factors place a range of pressures on the world’s machine tool builders (MTBs).
When working with MTBs involved in turnkey projects, each partner is deeply involved in the installation, adjustment and start-up work for technical and tooling equipment that is intended for the end-user. Efficient functioning of complete and often complicated technical systems to meet customer requirements is a fundamental need not only for project management but for project completion and success. This includes integrating the supply, mounting, adjustment and initiation of all interrelated elements while concurrently ensuring that all the elements work as a single cohesive system.
Although metal cutting tools are always a vital part of each project, it often happens that minimal time is allowed for the balancing and tuning of the tools. As a result, additional human resources are required to complete these essential tasks, meaning that experienced tooling assembly specialists need to be on hand to perform complicated procedures in a short time space and in unfamiliar environments.
Sometimes essential supporting equipment is not supplied, and may even be missing when needed for adjustment procedures. In addition, the tools and their accessories are often packed in different containers, causing unwelcome time losses when searching for necessary components.
The supply of complete assemblies of rotating tools for complex turnkey projects is thus important. Tooling companies such as Iscar therefore have specialists that are in constant cooperation with MTB companies involved in the management of large turnkey projects, in order to study and interpret customer needs and provide appropriate and effective solutions. These comprehensive schemes save time and cut down on the workforce required for start-up procedures, especially for larger projects. Each proposed turnkey package integrates distinctive features to maximise efficiency and simplify project implementation.
Tools are fully assembled, adjusted, and the individual tools are supplied with assembly and tooling layout drawings. If needed, each assembly can be equipped with electronic sensors for data management.
For projects using tools intended for high speed machining, tool or assembly balancing is able to be performed by employing appropriate technical equipment and software for theoretical analysis and correction. The instruction guide includes an assembly drawing containing data related to balance characteristics and relevant data from balancing test results.
Different forms of tooling layout representations can be prepared according to the complexity of the technological process or upon customer request.
Assembly Identification And Designation
Each tooling assembly is clearly marked according to its designation in the appropriate technological process with a code, tool number and other attributes necessary for tool identification within an automatic management system. This information is supplied with a customer report containing data related to the tool’s dimensions for quality assurance inspection.
Secure, Identifiable Packaging
An often overlooked aspect of cutting tool supply with turnkey schemes is packaging. Secure packaging ensures the safe delivery of tools and assemblies to customer sites. It also helps to guarantee that all dimensions that resulted from previous adjustment and balancing procedures are preserved.
Well packed, assembled tools can be supplied into secure wooden box for multi-usage purposes. A common situation for large MTB projects is that a tooling assembly initially arrives at a machine producer’s facility for test, then, if applicable on to a local MTB dealer, finally to the end-user’s site. If at one of the stages there are no dedicated places for tool storage, secure and re-useable packaging can play the vital role of a temporary “warehouse” during each phase of the project and when it travels between each location.
A unique identification system has been developed, enabling a quick and easy search system. This allows a requested assembly to be efficiently located even amongst a huge quantity of supplied containers.
Effectiveness In Turnkey Projects
When the appropriate steps are taken for tool assembly, the benefits of maximised productivity and effectiveness in turnkey projects can often be seen in leading machine tool builders of multiple, large and complex projects throughout the world.