Bar turning: the it's always been done this way cliché
I HAVE NEVER BEEN ABLE TO STAND THIS PHRASE, IT GIVES ME THE IDEA OF GIVING UP, OF NOT EVOLVING TO MAINTAIN THE STATUS QUO AND ONE'S OWN LITTLE COMFORT ZONE.
I'm tired of "that's the way it's always been done!"
I have never thought of myself as an innovator, only as a deep connoisseur of my work. This has led me, almost unbeknownst to me, to be known all over the world for my turning machines.
Throughout all this time, I have "clashed" with ideologies based solely on this phrase: "That's the way it's always been done...".
I have never been able to stand this phrase, it gives me the idea of renunciation, of not evolving to maintain the status quo and one's own little comfort zone.
What I see going on and on like a broken record stuck under the needle that keeps repeating the same little song over and over again, is - for example - bar turning.
Those most 'experienced' in this field would immediately respond with this statement: "If it has been done this way for so many years, it is because it is the most logical production system...!" thinking to silence any form of innovation.
I do not doubt that it is a logically correct system, but what everyone ignores is that it is an incredible hidden cost generator.
But follow me and let's go into detail. When a bar is inserted, as it cannot be cut, it is put into rotation with the spindles, it - obviously - starts to vibrate, unless the bars are perfectly balanced.
You can opt for very precise bars, but they are more expensive and give no added value to the turned part, they only serve to reduce vibration. The second option is to equip the turning machine with a sophisticated bar feeder that can reduce vibrations, although they will not be completely eliminated.
As above, it gives no added value to the turned part, only higher production costs.
Well, let us continue with our analysis. This type of machining is just a succession of problems that are not solved but circumvented without benefiting anyone!
But still someone insists: 'Yes it has always been done this way'!
It is at this point that the ideas to circumvent the problem begin, but not to solve it.
They start with lowering the revs to reduce the effect of the vibrations.
So with a reduction in revs, what could possibly happen other than having the positive effect of reduced vibration? The obvious still holds sway.
The cycle time is increased and this entails costs.
And I wish that was all! Even in this element of fake resolution, costs are doubled. Quality decreases because if the tool is designed to work properly at a certain speed, and excuse me for getting funny at this point, there will be a reason why they do it that way...
So, as a result we will have parts to scrap or grind.
Reject = costs
Rectification = costs
In this article you can see that, whatever solution or gimmick, it only resulted in production disadvantages leading to various damages.
> Worn-out machines before their time
> Tools worn out before time
> Huge wastage of material (not all the bar reaches the end of the machining process)
> Time wasted in grinding
> Time wasted replacing parts
> Money wasted buying replacement tools, bearings, etc.
> A sequence of problems that remind me of the broken record of "Eh but it's always been done this way!"
Think about it for a second.
You buy a Ferrari (congratulations on your purchase), an engine designed to hurtle along at high speed. Furious horses just waiting to run free. But you, for a variety of reasons that we won't go into here, never exceed 30 miles per hour... After a year or so, how do you think the engine of that Ferrari looks? Some horses will have been hurt and will not run any more.
What was designed to move or rotate at a certain speed will struggle to do so…
I mean, this Ferrari will require quite a bit of labour right at its heart....
Starting from the fact that a turning machine costs a bit more than a Ferrari, I really struggle to understand how you discard innovation to resort to gimmicks that will only backfire on you. Justifying it all with 'that's the way it's always been done...'
The sad truth, dear entrepreneur friend, is that the innovation is there and many are using it: the multi spindle CNC lathe Linea Spindle.
This leads to lower prices as costs are avoided by using multi-spindles that solve the problems I listed above, the sooner you realise this, the more you reduce the possibility of being cut out of the market.
As I told you at the beginning, I never thought of myself as an innovator, but the reality is that, thanks to the experience and development within my company, I have eliminated the hidden costs that those types of machines have.
I would be happy to discuss this with you in depth and prove to you, in my company, that this is really possible.
If you are still not convinced, request my book for FREE, then let me know what you think.