Sescoi Helps CA Tooling Cut Machining Cycle Times

Sescoi's WorkNC software and Myworkplan job management system have helped CA Tooling, based in Lynchburg, Virginia, to cut machining cycle times by 25 per cent and generate 15 per cent more business. Specialising in foundry tooling and general machining, CA Tooling is planning to open an 8,000ft2 (743m2) facility that will nearly double its present capacity. The speed of expansion was a key driver for investing in new systems. Darrel Gallier, tooling shop manager, said: 'We were having a few mishaps with tool and holder collisions, which prompted us to look for new software.

'WorkNC [computer-aided-design/computer-aided-manufacturing software] came out on top for the way in which it reduces the number of rapid moves and keeps the tool in the job for much more of the time,' he added. According to Keith Kessler, machine shop manager, the increasing levels of business also required changes to the company's management methods. He said: 'We needed a management system that would quickly produce accurate quotations and manage the growth in our production levels.

'The Myworkplan job management system can interrogate old quotes and similar jobs; this way, the quotation is immediately half finished. 'Once the software has been set up with our rates, we can be sure that we won't miss any items or processes,' added Kessler. WorkNC's reliability has had an impact on the way in which CA Tooling produces its toolpaths, according to Sescoi. Machinists are responsible for the programming and machining of a complete project. 'A block of 4140 tool steel can cost around USD50,000 [GBP30,000] and we typically machine away 60-70 per cent, so the reliability we get with WorkNC is crucial for our success,' said Gallier.

Tool and holder collision checking in the software enables the company to operate seven days a week. Finishing operations can often take 60-80 hours with laser tool probing checking for tool wear. Gallier continued: 'We frequently machine down to a 1mm fillet, so WorkNC's smooth cutting trajectories help us to avoid shock-loading the tools and keeps the stresses within them as low as possible. 'Not only does this increase tool life and reduce wear, but it enables us to run unmanned for long periods. 'Furthermore, the software's automatic cycles and the way in which the tool stays in the job for as long as possible, has resulted in a 25 per cent reduction in machining times,' he said. Kessler added: 'We have a customer and supplier database within the software that makes it easy for us to keep up with our customers.

'We can, for example, query all plating jobs irrespective of customer, which gives us a better understanding of costs and manufacturing times. 'We can also keep track of supplier pricing and delivery times, thanks to the early warnings provided by Myworkplan,' he said. As well as rapid quotation production, achieved through the analysis of computer-aided-design data and reference to historic quotation information, the software has helped CA Tooling to adhere to delivery schedules and keep track of the individual costs associated with each job.

Kessler continued: 'Without Myworkplan, we would have been unable to continue to expand. 'The software has greatly reduced our administrative load, automatically generating purchase orders and producing quotations in a fraction of the time,' he added. Both WorkNC and Myworkplan are supported over the internet and through self-teach tutorials, which are intended to help employees to increase their skill and efficiency levels.