Don’t lose your money in machining

Proudfoot Consulting recently released its 2008 Global Productivity Report—an annual study of sectors that includes automotive, energy, mining and general manufacturing. Much of the 88-page study, which you can download, is founded on feedback from more than 1,200 managers in 12 countries. The managers were queried about current productivity levels, potential for productivity gains and barriers to improving productivity. Read more on IMT.

Among other findings, this year’s report reveals that managers around the world believe they have the potential to boost productivity by an average of 14 percent next year. However, they will likely leave 30 percent of that possible productivity on the table. Managers in the United States say they will lose out on nearly half of their potential productivity gains.

If you similarly feel your shop will fall short on its potential for improved productivity, then you’re likely ratcheting-up your efforts to improve the efficiency of your current processes. The fundamental way this happens is by identifying and eliminating waste, which is the prime goal of lean manufacturing. If that’s what you’re looking to accomplish, I suggest visiting our Lean Manufacturing Zone. There you’ll find a collection of stories that reveal how other shops have implemented lean techniques such as 5S organization, value stream mapping and visual workplace initiatives to reduce waste.

Here are a few stories that I think you will find particularly helpful:

• This Shop Really Shines…And Sorts, Simplifies, Standardizes And Sustains—The 5S principles proved to be a powerful prelude and prerequisite to lean manufacturing at this aerospace job shop.

• Lean Manufacturing For The Job Shop—Lean practices are not just for predictable production. Here are the common-sense ways a low-volume job shop has moved toward leaner processes.

• Picture-Perfect Manufacturing—Value stream mapping is a graphical tool that this contract manufacturer uses to create a production process with little waste.

• Lean From The Get-Go—This shop was lean from day one. Its visual management tools form its lean manufacturing foundation.

Our Lean Manufacturing Zone is one of more than two dozen knowledge centers covering specific machining and manufacturing topics. You can find them listed down the left side of our home page at www.mmsonline.com. We established these zones to make it more efficient for you to find the important information you need on your journey to boost productivity.

Twitter Worm/Virus Koobface

There are numerous reports of a new Twitter worm that steals your log-in information and spreads its evil cause. The worm comes in the form of a direct message from someone you may know, and maybe even trust.

The poster child for these attacks has been the Koobface worm, which has been circulating on Facebook and various other sites for several months. However, the term worm is something of a misnomer in this case, experts say, as Koobface in fact comprises a number of different components. In addition to the social networking propagation components, Koobface also now includes a network of malicious Web servers, URL checkers, a CAPTCHA breaker, a rogue antivirus program, data stealers and search-result hijackers, said Ivan Macalintal, a senior threat analyst at Trend Micro, in a presentation at Virus Bulletin 2009 here Thursday.

And that litany of capabilities doesn’t even include the botnet and associated command and control structure that Koobface has built. The botnet control is done over HTTP, and the updates that the Koobface authors make to the program, which sometimes happen as frequently as once a day, usually change the C&C structure, as well.

“It’s an unfinished product at this point and it’s in perpetual beta,” Macalintal said.

In June, Koobface still had just two main C&C servers controlling the botnet. A month later, after continued efforts from researchers to disrupt the botnet, the Koobface authors updated the infrastructure, adding a layer of proxies and making it more difficult to identify the specific servers controlling the bots.

Koobface also is now using blogs that are set up automatically, usually centered on a major news event and filled with entries with malicious links. The links lead to phishing sites or sites that host the Koobface malware itself.

And it’s not just Facebook that’s taking the hit. Twitter also has emerged a major target for attackers looking for phishing victims, personal information on potential victims and anything else that could be of use. There have been some incidents of botmasters using Twitter as a command mechanism, although experts say this is not of much use.

“It’s not the best means of command and control, because it’s easily blocked after detection,” said Costin Raiu, (above, right) a security researcher at Kaspersky Lab, who gave a joint presentation with Morton Swimmer (above, left) of Trend Micro, on Twitter attacks.

Raiu and Swimmer are working on separate projects analyzing the volume and nature of threats and attacks on Twitter by pulling tweets from the site’s public timeline and putting them through a variety of automated analyses. Much of the activity right now consists of spam from automated Twitter accounts, malicious URLs leading to phishing sites and porn.

Unsurprisingly, this issue has not been addressed by Twitter on their blogs, just as that huge exploit that was discovered last month wasn’t. Twitter should probably do a better job of communicating such problems to users before more people fall victim. Mashable notes that they did contact the company about the issue, and they are aware of it, and “on the case.”

Green Anodizing

When aluminum is anodized, it receives a thin-film coating of aluminum oxide that protects the aluminum against further oxidation and corrosion. The anodizing process, however, occurs in several stages, and although it is regarded by many as an environmentally-friendly process already, new innovations have led to the further “greening” of aluminum anodizing. Several companies follow unique steps to keep anodizing safe and green.

The first stage in almost any basic anodizing process involves cleaning the substrate. Cleaning serves several purposes, but its main function is to remove and eliminate surface contamination that arises as a result of various forming processes (such as extrusion), manufacturing dust and lubricants, and additional workplace grease. After cleaning, the substrate is then rinsed to ensure previous reactions are completed and to further reduce the likelihood of cross-contamination.

After cleaning and rinsing, etching can begin. Successful etching reduces the substrate surface in order to produce a smooth, matte finish and eliminate any surface flaws generated by forming processes. Once the surface is sufficiently etched, it is then deoxidized and any additional metal oxides that may still remain after cleaning and etching are also removed. The surface is then deemed “active” and ready to undergo anodizing.

To create a thin-film anodic coating on the aluminum substrate, electricity is applied to the substrate to induce oxidation. The result should be a thin-film anodic coating comprised of aluminum and oxygen that will serve to protect the integrity of the component. If a colored coating is desired, an additional metal can be electrodeposited. Once anodizing is complete, the coating is sealed with a metal-based compound.

The anodizing process described above is already a relatively eco-friendly process. Toxic metals are not generally used, and very few toxins are released as a result. Additionally, byproducts are typically recyclable, and the aluminum end-product is also non-toxic and safe for a wide array of consumer uses, including those that designed for cosmetic and food and beverage applications.

To make anodizing even cleaner, companies such as Anomatic, Lintec, and DAC take several measures to make anodizing a sustainable, green manufacturing process.

For many companies, this process begins with the selection of aluminum—a metal that when recycled is already in a metallic state—which requires no additional purification and reduction, merely melting. Any leftover aluminum scrap that accumulates during the manufacturing process can be recycled. Additionally, recycled aluminum alloys (such as 3004) can be used, but care must be taken to ensure that the alloys meet regulations because some recycled alloys can contain higher amounts of heavy metals.

In the drawing process, when aluminum is formed and pressed into the desired shape, several kinds of oil and grease are used. Oil can typically be removed and reused, while scrap aluminum with oil residue can be subjected to a special oil removal process before being recycled. The aluminum substrate itself is degreased to recapture oils for reuse. The entire process doesn’t create any toxic byproducts or emissions.

During anodizing several inorganic acids are used to dissolve aluminum. To prevent contamination and pollution, the aluminum component is rinsed between stages and the excess acids are treated before being sent to a wastewater treatment plant.

Through applying these processes at various stages in anodizing, companies are making responsible strides toward an even cleaner kind of anodizing. The careful monitoring of waste, proper material selection and handling, and attention to ways in which all byproducts can be re-used or recycled has played an integral role in the greening of anodizing, and companies that abide by these practices and lead by example have been increasingly recognized for their commitment to greener anodizing.

Siemens Releases New Control

The much hyped Crack the G-code project will be unveiled soon. It was a marketing campaign designed by seimens to promote their new CNC hardware platform. Here is a link to information about their media event.

“Siemens is introducing a new CNC hardware platform that will
allow job shops across the world to break free from G-code
intensive programming and discover CNC that’s easier to use.
Join us for this exclusive online media event and receive a sneak
peek at a productivity breakthrough that “Cracks the G-code”

GE FANUC joint venture Over With

CNC books and tools

On August 18, 2009 FANUC LTD. announced that the GE FANUC joint venture will be dissolved. As the result of the dissolution, FANUC AMERICA will become both the service and system supplier for FANUC CNC in the Americas. This transaction is subject to regulatory approvals, and is expected to be completed in 60-120 days.

Thomas S. Migala, FANUC AMERICA President and CEO said, “The dissolution of the joint venture structure will afford FANUC AMERICA an unparalleled opportunity to bring even more value to our customers as we continue to focus on providing factory automation products and services. This action will allow FANUC AMERICA to better serve all customers in the Americas with all CNC factory automation products and services.

This action is clearly in the best interest of our customers and in the best interest of the respective parent companies.. For FANUC AMERICA, this is a culmination of the natural state of the business. It is clear that FANUC LTD. and FANUC AMERICA have set the future strategic direction to further invest in the CNC business in the Americas

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Factory Noise Control Systems

Just as there are regulations dictating the amount of time a worker may be exposed to chemicals, there are also standards regarding the amount and level of noise a worker can endure in an industrial environment. In order to manage noise levels, the noise can be either controlled at the source or noise reverberations minimized. Because it is often difficult to eliminate a noise at its source (many machines are, by nature, quite loud), attempts to limit noise reverberation through the addition of noise absorbent material is often necessary. However, odd factory dimensions can make the reverberation of sound uneven, and thus prevention is more complex.

To understand how reverberation differs from source noise and how best to minimize internal factory sound, it’s helpful to examine the terms associated with the relay of sound. Essentially, there are three points at which a noise can be controlled: the source, the transmission path, or the receiver. A noise’s source, or point of origin, is not always singular. In a busy factory, there could be countless noise sources all operating simultaneously. Additionally, some machines may contain several noise sources, which can further complicate the issue of identifying a source.

The next stage, the transmission path, refers to wave transmission and the manner in which sound and vibration travel from the source to the final receiver. Transmission paths can range in form and content, from direct airborne sound transmission to reverberated sound delivery. Additionally, sound can be transmitted through the ground, ducts, liquid, surrounding structures, or a combination of means, making it sometimes difficult to trace a noise’s direct path.

Once the sound has travelled along its transmission path, it reaches a receiver, the end person or structure that receives, absorbs, or hears the sound. The recipient of noise is the party most affected by it—be it an instrument recording sound waves or a worker—and is therefore the primary consideration in noise control. Regardless of who or what receives the final transmitted sound, it’s possible to control the noise so that it falls within a predetermined acceptable range.

Noise control can occur at the source, along the path of transmission, or at the receiver. If possible, noise control should occur at the source. However, in many cases this isn’t possible, and therefore control along the transmission path must be tried next, although this is often more expensive and more complicated than controlling the sound at the source. Controlling noise at the receiver can be cost-effective, but is also complicated.

Noise Control Methods

Depending on what stage of transmission a sound is controlled, there are several methods for minimizing noise. Controlling sound at its source can be accomplished several ways. First, examine the work machine to see if the mechanics or process can be altered to decrease the sound level. Dampening treatments can be applied to processes that create ringing and large sounds, such as anvils and hammers. Additionally, a dampening pad can be used underneath the work piece to further absorb noise. If possible, place the machine within an enclosure to further reduce the spread of noise.

When seeking to minimize noise along the transmission path, other methods may apply. Re arranging the layout of the floor so that the source is farther from the receiver, or so the transmission path is softened, can be a good place to start. Using absorbent padding along the walls and ceiling can further reduce reverberations.

If the receiver of the noise is a person, employing more than one machine operator can help reduce noise exposure, as can the use of ear plugs or ear phones to block out sound. Reducing machining duration can also help. If a noise problem persists once these methods have been exhausted, the next step requires close examination and the possible revamping of the acoustic properties of the workplace.