Bearing Up After the Downturn

Plant Manager Derek Rozon uses 5-axis machining to reduce cycle times and improve part quality.

Don’t let the name fool you. J/E Bearing & Machine, Tillsonburg, Ont., is much more than a bearing manufacturer. Since 1983 this 26,000-sq.-ft. job shop has been providing parts, components, assemblies, and subassemblies to numerous industries, including food processing, energy, and military and defence.

After a few tough years following the 2008 recession, J/E just finished its most successful year in company history, creating the need for more powerful manufacturing equipment and accompanying CAD/CAM software to optimize production volume and lead times.

More Efficient Operations

The company is a low- to medium-volume job shop that runs many repeat jobs with numerous setups, and its short- to medium-run jobs continually turn over.

To meet this demand, the company expanded its install base from two CNC machines to 13, including three new 5-axis VMCs, one being a large machine with 141 in. of travel in the X axis. This machine is dedicated to producing similar parts of differing lengths and configurations for a multiyear defence project.

For its programming needs, the company uses the Mastercam® suite of products from CNC Software.

The 5-axis machines have provided the company with the ability to take on more jobs, making the need for an easy-to-use CAM program all the more important.

Plant Manager Derek Rozon, who was the Mastercam programmer for 23 years, found it was becoming difficult to balance the job duties of plant manager and programmer, so he hired Miguel Ruiz four years ago as the company’s full-time programmer.

Introduction to 5-Axis

Programmer Miguel Ruiz uses dynamic toolpaths that engage more of the tool in the cut to reduce air cutting and improve metal removal rates.

After introducing Ruiz to 5-axis machining, Rozon sent him to local Mastercam reseller In-House Solutions, Cambridge, Ont., for multiaxis training.

“It’s a different world when you start looking at 5-axis from a production standpoint,” said Rozon.

According to Ruiz, the software has helped in reducing setup times and improving overall workflow, especially when programming for J/E’s largest customer, a defence contractor that sends its orders for 3-D parts in STEP format.

“We need to deal with a lot of stringent documentation for this client,” said Rozon, who explained the company had to beef up its ISO standards to do work with the military.

Although the parts can be complex, new software allows them to be programmed efficiently, and simulation helps ensure that there will be no in-machine interferences that could cause damage.

Despite the fact that complex programs that incorporate dynamic motion can generate a great deal of code, they present no problems to the new machines because their controllers have large amounts of memory.

“I put a 13-megabyte program on the DMC 80P duoBLOCK® today,” said Rozon. “Those large programs will become the norm because of more efficient material removal and reduced tool wear.”

Dynamic Machining

The ability to cut expensive materials to exacting specifications with reduced cycle times has given the company a distinct advantage. Many of the parts J/E is called upon to manufacture start as mono-material billets from which large amounts of material must be removed.

J/E Bearing & Machine, Tillsonburg, Ont., has invested in new software, machine tool technology, and staff to stay at the forefront of the manufacturing industry.

In one application, a 270-lb. block of steel will be cut down to only 40 lbs. In another job, 3,000 parts start out as an 85-lb. block of high-strength steel and end up weighing 14 lbs. at the end. Yet another project starts out as a 10-in. round disc that ends up being a 6- by 7-in. piece that is not quite square.

The company roughs out these parts using toolpaths that incorporate Mastercam’s Dynamic Motion technology, Ruiz said.

“The program keeps the tool continuously engaged with the material so there isn’t a lot of jumping around or air cutting,” said Ruiz. “Additionally, the dynamic toolpaths can utilize the entire length of the tool to cut, rather than just the tips.”

“Instead of taking an end mill and using a million tips, you take smaller radial cuts with a much larger depth,” explained Rozon.

When the entire tool length is used, tool wear and breakage are reduced, further saving time and manufacturing costs.

“We always look for opportunities to optimize our manufacturing processes,” said Rozon.

The programmer, operators, Mastercam reseller, and tool vendors have all contributed, he added.

J/E’s investment in new equipment and the latest version of the software was the result of a careful analysis by Rozon and the management team.

“With these systems, we know our quote will be where it needs to be to win the job. We can get to the happy medium where your customer is satisfied with the price you are giving them and, at the same time, you know the job will be profitable,” said Rozon.

Rozon’s team consists of Ruiz and 13 to 15 machine operators spread over two shifts. Machine operators are discouraged from randomly changing programs. However, if some change must be made at the machine, Ruiz routinely updates the program so that manufacturing processes will be consistent from run to run and machine to machine.

Looking to the Future

“2016 will be the busiest year in company history,” said Rozon.

The defence project, which is under contract until 2020, was won on price, but J/E’s reputation for reliability, on-time delivery, and quality certainly helped. In addition to meeting stringent ISO standards and military specifications, the company’s ability to meet exacting requirements and reasonable turnaround times via its dynamic machining capabilities has opened the door to working with companies it otherwise might not have been able to do business with before.

During 2016, J/E plans to add Vericut software, as well as more fixturing, vises, and other accessories, in an effort to reduce setup times even further. They also continually explore new ways to do existing jobs.

The company also is investing in the future of manufacturing.

After a visit to his old high school, East Elgin Secondary School, Aylmer, Ont., Rozon noticed that the shop looked much the way it did when he attended the school from 1992 to 1996.

“I saw that the kids were graduating with old technology that is useless to them,” he said.

He then approached Mastercam, In-House Solutions, and the high school about updating the technology. With their help, J/E was able to donate eight seats of Mastercam to the shop program.

Rozon said that a lot of schools have lost their tech programs because machines, tooling, and materials are often cost-prohibitive. Hopefully, this school, which is only 20 minutes away, will be able to keep its program going at a high level and be a source of J/E employees to support the company’s growth.

By investing in equipment, software, and people, J/E Bearing & Machine has found the right strategy to win the ever-changing manufacturing battle.

Contributing writer Marie Pompili can be reached at mariepompili@gmail.com.

J/E Bearing & Machine, 800-265-9375, www.je-bearing.com

Mastercam, 860-875-5006, www.mastercam.com