In the Cummins plant in São Paulo, Brazil, the problem of boring of the truck diesel engine C series cylinder line 120 process has become more and more serious. An old machine tool used in the cylinder boring process is constantly failing, with losses of up to R$ 80,000 (over 30,000 Euros) per year of downtime and approximately 30,000 lei (12,000 Euros) in 2011.
Although Cummins has a team of experts and suppliers at the Sao Paulo plant, the factory management believes that the existing technical measures cannot completely solve the above problems. So they found Sandvik Coromant and came up with an expedient: to buy replacement parts for the old machine that is constantly failing.
But Sandvik Coromant has put forward a different idea: through the use of new tools, and automatic re-planning online feed line to process the contents of the original machine bed transfers to other newer and better flexibility of the machine, so 120 The process is completely eliminated. Perhaps most critically, the new equipment provides a safer working environment for operators.
Cummins executives accepted this approach after listening to the introduction by Sandvik technical salesman Antonio Granzoto. Cummins manufacturing engineer Emerson Carlos dos Santos said: "Before we saw someone trying to come up with a solution, but it didn't work. But when we saw his introduction, we thought, 'Scorpio, we have to try one Try it. It may work."
The results later reflect the cooperative relationship between Cummins and Sandvik Coromant, which has been stationed in the factory since 2005. The two companies jointly established an 11-person executive team, 8 of whom came from Cummins and three from Sandvik Coromant, and the two sides re-coordinated the entire processing line.
Cuamins manufacturing engineer Thiago Vasques said: "The initial team size was small, and later programming problems were also included in the scope of cooperation. This is a big project, with many different people involved. Our idea is to involve as many people as possible. We have 8 machine tools that can be maneuvered and require excellent operator involvement."
The realignment of the production line encountered two major challenges. First, replace the 120 process with the new technology of “damping toolâ€. Secondly, all other process contents on the old machine tool should be transferred to other equipment on the production line without increasing the processing time. The production line beat can only be based on the slowest device beat.
Granzoto's original plan stipulated that the processing time of any single machine would not exceed 12 minutes. Therefore, this requires restructuring the entire production line. However, if the adjustment is successful, it can save R$ 700,000 per year (270,000 euros), far exceeding the cost of the project. This program worked. Even in the early days of operation, the new system saves R$ 180,000 (nearly €70,000) per year, only for operating expenses. Such “joint cooperation†solutions have always appeared in all aspects of the collaboration between Cummins and Sandvik Coromant.
Geraldo Sumitomo, Cummins Manufacturing Director, said: "There is no doubt that the C-cylinder project has had a huge impact not only on cost but also on people-oriented. We are very happy to work with Sandvik Coromant. We have a first class Technical support such as tools and processes. Only this year, we have 8 new tools in the test phase."
Sumitomo said: “This type of project is very common. They may come from one party or the other, but all improvements and development work is done by both parties.â€
At the Cummins plant, the 120 process is the boring process of the engine block, with a monthly output of 1,200 units. Repeated downtimes are a major problem, and there are also security risks. Sandvik Coromant does not mechanically improve on a single machine with a single function. Instead, it uses its efficiency improvement program to create new solutions that disperse its functions into other machine tools.
The key is to use a new “damping tool†that can accurately perform a boring task with a diameter of 120 mm on a flexible machine (rather than a single-function machine with support). The vibration-damping tool post with anti-vibration allows long-distance machining and allows the tool to work in CNC machines with automatic tool change (rather than in a dedicated machine).
It is essential to reduce the time required for roughing the camshaft housing bore from 6 minutes to 2 minutes. The entire line was re-adjusted and the other seven processes were transferred to the Heller and GROB machines. New processes and tools reduce costs while increasing efficiency and saving production time.
Emerson Carlos dos Santos said that the best ideas are all thought of when drinking coffee. He said: "We always need to reduce costs. Thiago [Vasques] always thinks about knives, we exchange ideas with the Cummins team every day."
In addition, in order to get a major new project every six months, they meet every Friday and hope to explore ways to strengthen cooperation. Granzoto said: "The opportunities for improvement are everywhere."
In recent years, reducing costs rather than expanding or restructuring production has become the overwhelming focus, reflecting the development trend of Brazilian metal manufacturing. Brazil has a huge domestic market and neighboring markets such as Argentina. However, the financial crisis in the United States and Europe has been hit hard by the appreciation of the Brazilian currency. Although the Brazilian economy has been successful, it has also led to a general decline in its manufacturing competitiveness. Compared with the previous year, the production of C-cylinders in 2013 fell by 20%.
Cutting costs is imperative, and we also need talented people in metal processing. Dos Santos said, “As long as we need new tools or new strategies, Sandvik Coromant will help. They understand us and our factories.â€
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