Easy transfer of work helps this mold company grow

Modern Machine Shop, May, 1995

Building a productive tool and mold company is dependent on monitoring manufacturing trends, and knowing whether or not using new technology could improve operations, according to Mr. Foreman. His company increased productivity by 50% five years ago by standardizing with a new tooling system. He had noticed that every toolmaker in the shop had a different way of mounting a tool, so by the time it reached the EDM department, the operator had to re-adjust it for work. Since this amounted to wasted time, and unnecessary work, Mr. Foreman began looking at his options.

After some research, he concluded that standardizing with an off-the-shelf tooling system was the way to go. With the diversity of work going through the shop, Foreman Tool & Mold needed accurate tooling that could handle any workpiece. According to Mr. Foreman, buying into an off-the-shelf system has many advantages.

"We have the ability to get replacement tooling we can use immediately," he said. "The added flexibility gives us peace of mind, and it saves us time. We don't have to scramble around to find what we need. Using an off-the-shelf tooling system is more efficient - and the economic advantages are obvious."

He investigated different tooling systems, considering several factors. He wanted accuracy, repeatability, durability and most of all, the "simplicity of a system," he said.

"What's important is the universal application of your tooling," Mr. Foreman said. "So we chose Erowa. This tooling can be transferred from our machining centers to our grinding operations, and to our EDM department for cavity and core work. Although we use both wire and sink EDM, we probably use wire applications more than most shops. We use the same Erowa tooling for all of it - it only makes sense."

Specifically, Foreman Tool & Mold uses Erowa's Integrated Tooling System (ITS) with its Agie machines: three machining centers, a full CNC EDM machine, and a wire EDM machine. Mr. Foreman likes the system's flexibility and compatibility for transferring work between machines. The company's workpieces are quickly and accurately positioned to known reference points and maintained at a repeatable accuracy of 0.00008[inches] - even when removed for measuring or inspection.

"This system improved our EDMing," Mr. Foreman said. "The positioning - aligning the electrode with the workpiece - was tremendous."

The need for simplicity carries over into a system's actual application, as well. In other words, the system must be logical and easy to use, he said.

"The transition from the old way was virtually overnight," Mr. Foreman said. "I started getting a lot of requests from the shop for the new tooling - no one wanted to go back to the old way. Then again, we have some pretty sharp people. When they see something that will save production time and he more convenient, they are going to want to use it."

Recently, Foreman began pursuing ISO 9000 certification. This kind of commitment to quality is essential in a tool and mold shop, he said. "For our customers, quality is a given. It's just understood - that's why they do business with us. Quality is that basic, and that important."

According to Mr. Foreman, maximizing quality should be priority in every mold shop. All measures should be taken to ensure that toolmakers can concentrate on producing quality work. A good tooling system will help workers perform with confidence.

"We have to be able to take a finished block and have the confidence that the burns are where they are supposed to be," Mr. Foreman said. "All toolmakers at every station should have confidence in the capabilities of their tools."

Although a machine tool can offer a high level of accuracy and a savings in production time, only the correct utilization of the tool can assure success. Standardizing already reduces set-up time, but add to that value of confidence. Knowing a job will be done right, a toolmaker at Foreman doesn't have to continually check and re-measure.

Additionally, the focus on quality naturally gives a shop the competitive edge, Mr. Foreman said. "Having a good tooling system is a good selling tool when we bring our customers through the shop. It's interesting to see their reactions. They're impressed, and they have confidence that we can deliver the quality they expect."