2. I think 35-70 minute setups are too long. I really don't want or care to hear your excuses on why it takes that long but if holding 0.002 is part of what's contributing to that setup and the customer only needs .005 or .01 then it is costing at least you extra by losing some machine time and potentially extra work.
You don't want to hear it, but that's never stopped me before.
I just want to be clear that our setup times might be timed differently than others. Remember I said "part to part"... here's how we time them:
- Last part(s) comes out of machine, measure stuff, wash, stack and move all parts out of the way
-------Time starts now-------
- Remove all tools
- Put in all tools for next job
- Remove last jobs fixturing
- Install next jobs fixturing, indicate where necessary (usually only along X axis for soft jaws)
- Run Setup Program (automatically sets all tools, updates all wear offsets from last run if applicable, then runs probe and sets all work offsets)
- Run Part Program
- Measure everything, make adjustments, run another cycle and measure again until good parts are coming out (usually 2nd cycle is good)
------Time stops here------ (only when next job is officially running)
The measuring part is where the big swing in times comes in. Some parts have maybe 5 things to really eyeball, mics and pins, done. Other parts have tons of critical features, gotta fire up the vision system for those, walk the parts in to the office, measure, go back and adjust, run it, then go back to the office and measure again. That really saps a ton of time.
I've stop-watched many of our setups and don't really see anywhere to improve. Of course if we were making 1,000 of each part number per month for the next 5 years, we'd be using dedicated fixture plates with vises all ready to go (most of our parts are too delicate for Miteebite stuff), but our runs are more like 100-500 or so with no guarantee of longevity at all. This run could be the last run ever, or it could be the start of a year or more of the same parts.
What do you attribute the new work to?
Work coming from your request for work on this forum? Changes to your website? Or, just plain coincidence of the work cycle, sometimes you're busy, sometimes nothing?
Some of it came from a couple of our competitors failing as a business, or simply customers getting tired of shitty or late parts. No RFQ's at all came from this thread. I didn't expect any, really, but I couldn't be looking at going out of business without trying everything I could think of.
Most of the turnaround was completely random. We didn't pick up any new customers, but a few old customers sent RFQ's out of nowhere. A lot of our current work load is long running, small 3D parts with some quantities in the hundreds. I'm really liking that stuff, plus if it keeps coming we can run it on the Haas and run the shorter cycles on the Brother and clean everybody's clock!