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V O I C E S Figure 1—Material Flow Network at a Department Of Defense (DOD) Supplier again and continue it until a state of perfection is reached in which perfect value is created with no waste. Here is why several of these highlypopular lean tools cannot address the complexity of a job shop. Identifying value is trying to deliver to the customer what they want, when they want it at a competitive price. This is universally applicable to just about any business. But, it is not that easy to achieve quality, cost and delivery when the benefit of learning by repeating the same work over and over again is absent, as is the case in any job shop. Value stream mapping (VSM) is a manual method. I have yet to see a single VSM that has mapped multiple interacting value streams that dynamically share resources. Besides, the “theory” of VSM is based on assembly line balancing. No job shop that is a multi-product remanufacturer or project-oriented custom manufacturer has a cadence (aka takt time) in their work flow. Nor does VSM have the ability to identify all the product families that may exist in any job shop’s product mix. One-piece flow cells are infeasible in job shops beyond a small portion of their product mix; instead, using group technology and production flow analysis, the job shop can be divided into two areas: One side consisting of flexible manufacturing cells (“minijob shops”) with each cell dedicated to a product family and the other side being a “remainder shop” where the spare parts, prototypes and one-off orders are produced. Flexible cells may not allow perfect one-piece flow, as in any assembly line. Still, due to increased proximity between consecutively used workstations, small batches of parts can be easily moved by hand or by using wheeled carts, short roller conveyors or Gorbel cranes. A job shop is a maketo-order (MTO) business; i.e., orders are pulled into production based on actual demand. In contrast, all the lean tools that suit assembly line production are based on a make-to-stock (MTS) inventory model. I see no reason to use tools for MTS production scheduling when there are tools for MTO production scheduling at our disposal, such as finite load order release, finite capacity scheduling, electronic Gantt charts, manufacturing execution systems, etc. I wholeheartedly agree that a job shop should pursue continuous improvement one part family at a time. U.S. manufacturers are now in the 21st Century and competing against countries where manufacturers have already availed themselves of the best consultants with expertise in lean and Six Sigma. If the United States can boast of innovation-driven IT giants like Google, Apple, Microsoft, Facebook, etc., this may be a good time for the hundreds of thousands of HMLV manufacturers in the U.S. to explore a new approach that could make them not only lean, but also flexible, agile and adaptable. Figure 2—Material Flow Network at a Defense Logistics Agency (DLA) Supplier 12 GEARTECHNOLOGY August 2012 www.geartechnology.com
Ipsen’s ATLAS ® integral quench furnaces are highly engineered, sophisticated machines that are easy to operate and maintain, all while being extremely cost effective. ATLAS delivers top quality uniformity through cutting-edge technology and design: • Intelligent controls, Carb-o-Prof ® , provide you with your very own electronic metallurgist • SuperQuench with adjustable oil speed and four 40HP agitators • Muffle system for uniform temperature control • Safety – all ATLAS furnaces are water-free for maximum safety • 30% less gas consumption • Recon ® burners – single ended recuperated tubes (SERT) ® The unique HybridCarb ® gassing system from Ipsen is an ultra-efficient gassing system designed to replace endothermic generators and other gassing systems. Its core strength is precision gas control. Instead of burning excess gas off, the process gas is reconditioned and reused, increasing efficiency up to 90%. Other benefits of HybridCarb include: • Quick and easy hookup • Increased carburizing efficiency • Reduces CO 2 emissions by 90% • Significantly less expensive to operate than endogenerators • Consumes significantly less gas • Environmentally friendly and cost efficient • Lowers heat output creating a more comfortable work environment • Powers up and down at anytime, quickly and easily For more information please visit www.IpsenUSA.com www.IpsenUSA.com SPEED UNIFORMITY EFFICIENCY
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Page 3 and 4: Plan to see us at IMTS! http://info
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Page 7 and 8: Think Big! Grind Big! IMTS CHICAGO
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Page 38 and 39: able for the machining of workpiece
Page 40 and 41: See Drake’s newest External Threa
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Figure 3—Rolling contact fatigue
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tance, a surface-densification tech
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Case Study Involving Surface Durabi
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Figure 4—Baseline Gear A, Mesh 1,
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Table 3—Roughness parameters of b
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Figure 17—ISF Gear A, Mesh 1: pos
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Table 9—Design requirements for I
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N E W S In Memoriam James J. Cervin
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N E W S In her new role, Codina is
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N E W S Sunnen Receives Global Pion
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MFN is Official Cooperation Partner
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C A L E N D A R September 10-15—I
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A D V E R T I S E R S i n d e x ADV
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A D D E N D U M Technology Mash-Up
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HÖFLER by KLINGELNBERG: Gear Hobbi
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