MT Magazine May/June 2022

FEATURE STORY

MAY/JUNE 2022

29

The Materials As previously mentioned, aerospace is the leading industry served, which probably goes to the point that 95% report machining aluminum. Additionally, primarily in aero, high temperature alloys (58%) and titanium (53%) are among the materials most processed by the shops, as they are seventh and ninth in the top 10. Rounding out the top 10 of metals machined are stainless steel (2), mild steels (3), brass (4), tool steel (5), bronze (6), copper (8), and cast iron (10). Only cast iron is below 50%, at 46%. The Personnel When it comes to skilled staff, only 18% reported that they have no shortage. Of those firms, they took a variety of approaches to address the shortage, with the predominant strategy being cross-training (80%). In terms of improvement methodologies being undertaken by these shops, the numbers are somewhat low. Fifty-three percent say that theyhave some continuous improvement activity. But then the numbers fall, with 42%performing 5S workplace organization, 32% benchmarking, and 30% cellular manufacturing. At the very bottom is lean manufacturing (5%), which arguably means that there are some huge opportunities for some shops to improve their operational fitness. This article was written by Jan Schafer, Kylea Dolezal, and Gary S. Vasilash. To learn more about “Top Shops” identified by Modern Machine Shop, attend the Job Shops Program at IMTS 2022. For details, visit IMTS.com.

Although CNC machines have been commercially available for more than 50 years, the types of machines that tie for third in terms of being on shop floors are lathes and milling machines – without CNC – at 62%. They are followed by horizontal machining centers (HMCs) at 58%. Taking the number of VMCs, HTCs, and HMCs into account, the dominance of CNC is clear. The median number of CNC machine tools is 16, with an age of seven years. What’s more, 86% of respondents report having CAM software (and 88% CAD), so these shops are well into CNC operations. Additionally, 58% respond that they perform lights-out and unattended machining, so it is clear that computer control is part of their operational regime. While it isn’t entirely surprising that plasma/oxy-fuel machines come in second from the bottom at 7% – after all, these shops are more concentrated on machining so there isn’t a whole lot of plate cutting occurring – what is somewhat surprising is that at the bottom, at 5%, are twin-turret machines. This could be a function of twin-spindle machines lending themselves to volume production and so are probably perceived to be insufficiently flexible for job shop applications. components, there is something of a dearth, with 9% reporting having the equipment. Still, there are 68% of the shops not using 3D printing at all. In the inspection arena, there is something that is both surprising and expected in the top spot for equipment: optical comparators, at 73%. This is surprising because compared to the coordinate measuring machine (CMM), which is in the second spot at 69% (these CMMs are in a quality department; shop floor CMMs are back in sixth place at 27%, ahead of a portable measuring arm at 24%; nothing is last, but still 6%), the optical comparator is a tech that’s been around for 100 years – which is not to say that it hasn’t been improved in that time. Its ranking is not surprising because when it comes to speed and flexibility, they are highly useful tools. One technology that has room for growth in the job shop arena is 3D printing, or additive manufacturing. Only 32% report they use the technology. Of that number, 60% are using desktop units for printing polymer materials. Stand alone machines, with more substantial work envelopes, are at 39%. However, when it comes to additively building metal components, there is something of a dearth, with 9% reporting having the equipment. Still, there are 68% of the shops not using 3D printing at all. However, when it comes to additively building metal

Hundreds of Builders, Thousands of Machines – Only One That Fits Your Shop

The Machine Tool Search Engine

Spindle: Milling

Direction: V or H # of Main Spindles:

Start Searching for Free Today.

Max. HP: Top RPM:

Machine Type:

Machining Center

Drill/Tap Boring Mill Milling Machine

TechSpex.com