Machining A Pierson Mini Pallet System! 1 of 2 

Great work. Over 35 years of manufacturing background here and I love what you are doing. My background is electronics but the same lean principles apply to an manufacturing process. I would highly encourage you to start Gemba walks. I come in 30 minutes early a couple of days a week and walk the production floor before the operators show up, this gives me a feel for where we need to reduce clutter or where there are production bottle necks. If I see a lot of full racks at one operation I look at where we need to balance production. I also do a daily walk while production is in full swing and just observe. If you want to established a quality culture watching production will tell you if you are effective. I would also encourage you to look into ISO 9001 and 9002, laying the foundation for certification early in the evolution of your organization will make certification easier later. Being ISO certified makes it easy to be approved as a supplier to larger companies and is a huge bonus for marketing in the military and aerospace industry. In my experience military and aerospace are the areas where small manufacturers in the US can compete with off shore companies. You don't have to be producing product that is directly used in those applications but if you are servicing companies that do you can be an approved vendor very easily if you have an ISO certification.

Two great guys discussing the "lean" approach and VMCs... a real treasure trove... and done while watching the VMC operating... just awesome. Thank you so much for making this possible!

I just stumbled across this video and I can't thank you enough for making this and putting it out there for the world. I know it is several years old but right on time for me and my company.

These Pierson/SMW colab videos are among my favourites on RU-vid. Great to watch for someone like me starting out in my own manufacturing business. thanks guys!

To make your chip auger work like majic... change setting 114 to 7 and setting 115 to 1. Setting 114 is how often it turns on (7 is every 7 minutes) setting 115 is how long it runs (1 is run for 1 minute). Turn it on with a M31at the top of the program. You also save on coolant, with chips drain in the tube.

Great videos. So packed with good nuggets of info that they really need watching multiple times to catch it all.

You guys are an amazing Duo !!! Even as a hobbyist, so many useful tips and tricks that I can use to lift my game :-) Many thanks to Jay for being willing to share his hard won knowledge and John for taking time out to make these videos.

Cant be afraid to push your tools john. Especially in production, "push it till it breaks and back off a little" was super common around my old shop.

Dude the hammer wrench combo. That's cool

These are easily some of my favorite videos on RU-vid.

I really think Jay is a genius. I'm sure he's hardly the first to implement LEAN manufacturing, but wow does he do it well! Very, very cool to see- thanks for sharing John!

Great video, more of these focusing on how folks manufacture things through the entire cycle would be great. Much better than a tour.

VF2 SS, SWEEEEEET Love that machine, super fast and super good price.

Loved the easter egg, love the hammer/vise handle. Doing so well my machine is more than half paid off after 4 mos. of running two customers mostly in plastics and I just got a surge of 4 quotes yesterday! Going to have to finance another machine soon. btw, my boy is loading and running the machine at 7 yrs old...(i'll link a youtube vid to your email shortly)

John, Haas has settings to turn on your chip conveyor for a period of time. Setting 114 is the setting for the interval for it to automatically turn on(10= it will turn on every 10 minutes), 115 is the amount of time it will be on (5= it will run for 5 minutes). All you need to do is either turn on the conveyor by pressing the button after you start the program or us an m31 at the beginning of your program, and your chip auger will turn on every 10 minutes (setting 114) and run for 5 minutes (setting 115). I hope this helps you. This is what I use instead of using manual NC in HSM.

Really interesting the insight on the management work and the overview boards. These guys are clever.

So cool that you went back to Jay's operation! Really like their product... hope to be using it to produce some of my own in the near future :)

Very cool, this helps alot. This past week I had 60+ orders come in for Canada day. One heck of a week.

Just a quick tip, you could probably speed up your cycle time somewhat substantially by programming the drilling cycle as a G73 chip break cycle rather than a G83 peck drilling cycle, as the tool does not retract completely out of the hole. Also in aluminum with a cobalt drill, I wouldn’t be afraid of pushing it 2X or maybe even 3X D per peck either. I’m sure you know this already but if not then you learned something! Cheers, Kade

Jay! IJK on that first G83 instead of Q. You don't have to worry about chip clearance if the drill isn't deep yet. Changing from a Q.25 to I.8 J.25 K.25 (the first peck goes .8 deep, subsequent pecks reduce by .25 and minimum peck is .25) on two 1.4 inch deep M8 tapped holes saved me 9 seconds per cycle without increasing tool wear or making unruly chips. If you make 100 parts per day and save 9 seconds per cycle, the annual time savings is 1.625 work WEEKS. :) In reality though, I'd switch to carbide on that first set of pecked holes, go around 6000RPM feed in rapid out and just be done with it. This is good stuff. Looking forward to part 2.

Jay and John: Thank you so much for sharing

I can only imagine Jay's products have been selling like hotcakes since you have been giving him all this promotion. Good business for both of you.

This is such a good video. So packed with tips and systems I can apply

Feet up, drinking a beer and enjoying every second of this video... Good life... :)

Great information..Thank you for sharing gentlemen.

Congrats on the new machine, John!

Take the QR code concept Jay uses to attach on the pallets you use to load programs, setup sheets, videos, etc. for each pallet you use on the vises / pallet systems, etc.

The way I keep track of drill life is looking at the spindle load of when the tool is first installed and as the tool started to ware down the spindle load will start to increase.

Very impressive shop and innovation here no question!

loved the project planning board

Some sort of server that can be updated from any computer that drives an similar looking board with led indicators in each "cell" could be a great way to improve the system. Any even having physical buttons on the board to update the progress that also updates the server document could be utilized. You could them be receiving notifications about status critical criterion from anywhere.

There's supposed to be an option on the controller to turn on the auger automatically at defined intervals. There's a video on the haas youtube channel about it

On that how fast you can chamfer, you really are trying to cut corners. ;)

+1 for the E-Myth. Required reading where I work.

What an interesting vid. Thanks John and Jay.

As a 3d printing guy. I find this fascinating.

We love our speed pallet! We are going to order blanks soon! Looking to hopefully order that 4th axis 4 station vice too! ;-)

@NYC CNC, at 30:30 you where talking about the auger and if you have it automatically on or operate it manually. Did you know there is a feature in the haas to have it on a timer? You can set the duration and interval with SET.114 and SET.115. ( ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-OGjkavRmFpw.html )

On that job with the 2 piece rotary, even still there's wasted time. Around 23:40 you've got the same tool running back and forth. I doubt that's intended? You should be able to prioritize cuts so that doesn't happen, at least in Mastercam. So fun to watch that run though. That's the kind of machining I like to see

What a great video. It's amazing to see a shop that implements "lean" smartly. Jay seems like a great guy. I would love to try to implement some "lean" concepts to where I work, and I'm a guy that hates buzzwords... hahaha! A couple of questions on this, John, mainly about their machining process: 1 - I see 4th axis setups quite often that are done to save the number of setups you would have if run in a vise. In this case, I don't know that I see the point... If you run it as is, you have a "prep op" (or as Jay calls it, OP 0), followed by OP1 on the 4th axis then OP2 in a vise. But, if you ran the job just in vises, you would still have the same number of ops - you would have his OP1 and OP2, followed by an OP3 for the one drilled and tapped hole. And as you said, you could probably run more parts per cycle using just vises; using the 4th axis, you're limited to 2 at a time. Lastly... although it doesn't apply because he already has the 4th axis, so why not use it, but... just using vises cuts out a whole lot of cost. An HRC like that would easily be over $10k, plus the fixturing, compared to $8000 at the most for four Orange vises. 4th axis stuff like this is still very, very cool. I could see where he might could get 3 or 4 parts on his fixture at a time, then you would REALLY be cooking. Your thoughts? Wondered if you and Jay talked about this outside the video. Neither way is right/wrong by any means! 2 - I guess this is more a comment than anything. It looked to me Jay was using a Kennametal Dodeka for his face mill. Correct me if I'm wrong. Let me tell you, those are FANTASTIC face mills. I highly recommend you get one for your VM3. We ran a job recently in 6061 aluminum. Not even using inserts for aluminum, we were getting a fantastic surface finish at 12000 RPM and 400 IPM. Ours is a 5-insert, 2.5" cutter. These cutters can either be used for slow, heavy cuts, or even psuedo-"high feed" cutting for roughing purposes. Up to .022 IPT in steel.

18:18 350 IPM at 8000 RPM with a 3 flute endmill. Chip load would be 0.014" per tooth. Is that possible?

I really love this stuff and the physical interfaces, but as a programmer it somewhat frustrates me because I think of the duplication of work - having to write new orders etc every time. I just want to slap a barcode (or something else that's machine readable) onto that card so bad.

33:00 - 33:27 What is Jay saying? I'm pretty sure I understood him. So the 'Z' zero is the center of the tombstone, I get that. That makes sense. But for the arbitrary 'Z' number, it should be fairly straightforward. The tool height in the offset is based off the Gage Line right? So that no matter what tool you have in there, that goes to 'Z 0.0' you see 'Z 0.0' in the program. If the height offset was Zero, the Gage Line will attempt to go the Program's 'Z 0.0' Maybe Jay means that it looks arbitrary because the 'Z 0.0' isn't the top or bottom of the stock I guess?? That makes more sense for most flat vise work, but for 4th Axis Tombstone work, the rotation center is the easiest to understand, and typical to program.

Amazing machining! Just curious what the radial DOC is that you’re using on the 1/2” doing the 1.8” Axial DOC?

For all that want it. The QR code to the assembly video is ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-UtgjtZLLqKY.html

Great ideas however you cant truly state that this is a lean operation.smooth but not lean. All that was done was simplify and streamline operations to 100's of manual processes. Need a part 1 guy carries a card to order. (Why isn't stock charted against orders? And inventory known) then another person updates a manual board. A machinist then has to walk and update said board and be updated from board. Everything on those boards can be automated in software and macros. But you added miles of walking to update and slave to a board.

I would consider replacing the boards with touch sensitive monitors and software dedicated to those progress charts - much more flexible, with many opportunities for neat features: better presentation (use of color for example,) real-time status updates over the network, and... er, right, yes, if you did not guess already, a former programmer who got into CNC over here. Sorry! :)

Really like these two video's so much good info . now to ask the noob question of the week, allowing for well changing the tool's buy hand and a lower quality of finish could you make one on the 440 . as i will never be buying one of the HAAS ????

So out of pretty much reflex I'd be inclined to give that rotary fixture a tailstock, but it obviously doesn't need one.

I thought the idea of chamfering was to cut corners 😛 😉

I Love VF2's.

Can you please tell me which model Haas rotary table that is?

wow, superfast, cutting no limits

About the chip auger programming: did you see the TOD about automating it? That should definitely apply to at least the new VF2, and I think the VM as well. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-OGjkavRmFpw.html

Thanks John and Jay for another amazing tour and loads of super helpful information. John, you might need to go to Boise and see if you can get a tour of Rekluse. Started in a garage, and now they are making their own robotic automated pallet changing system (VersaBuilt) which they design and manufacture. Here is a video tour ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-EOT9aXljkI8.html skip to 4:00 for a quick overview.

cool

I'm copying that job board idea

Just curious why not use a live center for rigidity?

I'm surprised those shelves work for him. I had to replace the crap wood with plywood almost immediately because as soon as I got weight on them they started sagging really badly.

John protip for u guys ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-w3Oc5SvXzM0.htmlm57s u guys where doing a repeat on that inside diameter i saw them doing with counterclockwise but it u have the first one 1 going clockwise and the second 1 counterclockwise the finish wil improve allot i started doing that little trick a while back and u wil be suprised by the results it yields stil dont know why this is but allot improved on it the actual ID or OD wil be more precize and a way better surface finish also no burs ( side note it wil be machined to a sharpness that wil cut u )

Can you order the tools in the toolholder so tool changes are faster?

Looks like that vise handle has a plastic mallet built in.

Just saying, just because you programmed at 360 IPM doesn't mean your machine control is reaching that. Depends on length of cut , if there is enough length between the accel /decell .. That's where more expensive machines make a difference, CHeck out HAAS VS MAkino video,, or OKUMA vs makino, they give you an idea ..

Yep aha!

Story to be told

"I've been trying to figure out how fast I can chamfer, but take pride in the work; you're not trying to cut corners" Well, technically ...

I cant scan the Qr code...

Why is he calling KANBAN KONBON? Like Rath of Kan. We say it Can ban like Ban as in Band without the D.

Awesome video! However, the IT in me is screaming "WHY IS THIS NOT SOFTWARE!?!?" This could all be done with enterprise resource planning software (ERP). It can handle sales, shipping, and purchasing to the Nth degree. I now how expensive software can get, but it needs to be digitalized. Even if it's just in Excel just so some aspects can be automated.

"We need it next day." ... translates to, not prepared.

Sorry but with a chamfer tool you are always cutting corners :)

👨‍💻2019 👉TechPorn oh no 😲 sleep can wait 👍🤪☕☕☕ 🕺 👉🐨 oz straya mate! cheers🍻maybe a ☕ none my friends or family have a clue about tech - i,m the only 25yr spring factory worker techy Nutter in family that researches & watches this stuff i asked a few times what's in their PC's > 👉😳🥺no IDEA i just turn it on 🤷‍♂️🤪🐨 guess im on my own here!BUT son & Nephews know a lot THESE videos R ADDICTIVE to Watch

Wow, that too-smooth camera panning is making me nauseous. Stop that please.

/ b7’

"We have to make this FAST " ......so it can go sit on a shelf till someone orders one !!

You run CNC machines to automate your manufacturing. Then you break your business processes into a thousand individual manual steps that take a bunch of people and creates a thousand points of failure. And on top of that you clearly are collecting all this data somewhere to analyze..... Which I'm sure has to be doubling efforts somewhere and introducing another source of possible errors.... Your accounting, inventory, manufacturing, sales and purchasing systems should all tie into each other and all those boards on your wall should be screens on your computers. You wouldn't stand at a keyboard and enter gcode line by line. That's what you're doing with your office management system. You should be able to give a customer a quote and if they decide to order, turn that into an invoice which will trigger inventory and parts assemblies and manufacturing tickets and packing slips..... All that info can be available from every phone or computer in your organization. You can even tie your customers into your website let them enter their own order....

He wasting a loot of time without tsc and carbide drill.... And this is production? This is why america loosing production. Two parts 27 minutes... Maybye its fake program for Propaganda, he dont want to sell his production technology.

man , some removal there

Instead of saying yep you could just listen...