For any precision manufacturing operation competing in today’s business environment, maximizing productivity and increasing efficiency takes on a critical role in order to turn a profit. This rings especially true for small and medium-sized facilities, including Advanced Precision Machining’s Colorado machine shop. By staking our reputation on meeting our client’s needs for high-precision parts delivered accurately, on-time, and on-budget, we are constantly in search of ways to gain a competitive advantage. Success and profitability are dependent on whether resources are being used in an efficient manner, and this has proven even more difficult given current economic conditions, supply chain issues, the skills/job gap, and mounting challenges CNC machine shop owners face as a result of the Coronavirus pandemic. All of this, coupled with an ever-increasing demand for high-quality parts, means that milling and machining businesses must place an even greater emphasis on efficiency and productivity. Thankfully, more modern technological advancements in today’s precision machining tools mean many machine shops have the ability to streamline their operations, and one such consideration involves transitioning from more traditional approaches to precision machining and implementing some form of automation on the floor. 

 Automating CNC machine shop operations is a big decision for any owner, but pulling the trigger and opting to automate certain functions has become easier as the use of more technologically advanced milling and machining centers has become increasingly widespread. More and more precision machine shops are now striving for “unattended” or “lights-out” capabilities that incorporate the best of what today’s machine tools and accessories have to offer. The idea is simple on the surface; Minimize labor costs for each part made, thus lowering overall production costs by allowing automation to replace manual labor. By improving workflow processes, automation can help solve many of the productivity challenges machine shops face by reducing machining cycle times, setups and teardowns, while at the same time increasing production/output, improving both efficiency and profit margins. Not to be confused with robotic automation, in a precision machining environment automating machining functions unattended commonly refers to the use of a CNC machining center accessorized with a tool magazine, an automatic tool changing mechanism, and most importantly, a multi-pallet changing system/device for parts to be machined. 

The use of pallet changers has revolutionized efficiency for shop owners, especially in an age where labor market deficiencies and the ever-present skills/jobs gap mean simply finding more qualified CNC machinists is not feasible. In simple terms, a pallet changing device is a part handling subsystem that enables a part to be loaded while another is being machined – somewhat like a tool changing system but instead of switching out tools, pallet changers allow the operator to change out an entire bed of parts. Pallets can be cycled outside the cutting area once completed as the machining center automatically brings in a new one. The integration of a “pallet pool” even allows for multiple part beds to be set up in advance and scheduled for future runs, letting a machine run unattended for quite some time. All of this allows for multiple setups to be built, or unloading operations to take place, while milling and machining goes on uninterrupted. CNC machinists don’t have to wait for the machining process to complete itself. The end result is a significant reduction in part cycle times and non-cut times (spindle-idle time). All of this adds up to increased productivity and a reduction in costs, including labor. 

When the decision is made to automate certain machine shop operations, there are options when it comes to choosing what type of pallet changing system is best suited to particular needs. Cost, space, a shop’s capabilities, and other factors such as production capacity all come into play. Manual pallet and shuttle systems are designed for small job, low-volume lots and are cost-feasible taking up very little space. Loading and unloading is done by the operator. Automated pallet changers (APCs) are designed to work with traveling-column or bridge-type CNC machining centers and typically feature electric servo drives for transferring and indexing pallets. Stationary, dual, rotary, towers, and shelving units – the list goes on. The two examples provided only scratch the surface of what’s available depending on machine shop needs and what various manufacturers provide.

The bottom line is that in today’s competitive precision manufacturing environment, one that is fraught with new challenges, no machine shop owner can let tools or CNC machinists sit idle. Pallet changing can save a lot of money in production costs by significantly reducing part loading and setup downtime.

Need help with an upcoming project? APM’s reputation for quality parts, on-time reliability and exceptional customer service cannot be matched! We’re happy to discuss any machining needs you have. Call us at 303.776.1910 or send us an email.

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont , or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.

To the uninitiated eye, a glance inside any modern machine shop will reveal a wide array of high-tech equipment ranging from multi-axis milling machines, lathes, routers and grinders, to electrical discharge machines, waterjets and plasma cutters. While this list is undoubtedly essential to the day-to-day operations of any facility, it’s Computerized Numerical Control (CNC) and the associated software, complemented by advanced programming languages, that’s at the heart of precision manufacturing processes. Today, most modern CNC systems have become highly automated and quite complex, augmented by a host of software suites, but a precision machined part in the end is only going to be as good as inputs used to create it. Thankfully, there is now a vast array of digital tooling utilities being used to augment and boost CNC milling and machining operations.  

At Advanced Precision Machining’s (APM) Colorado machine shop, we now have cutting-edge equipment at our fingertips, combined with the critical software necessary to make our business successful. In our tireless and dedicated effort to manufacture high-quality precision parts, and maintain our reputation for accuracy and on-time reliability,our CNC machinists have evolved to become skilled in all aspects of software drawing and design, code writing, and machine tool operation. In addition to the purchase order, scheduling, accounting, inventory and payroll software programs that are common to most businesses, the certified machinists at APM must heavily rely on a natural progression of software suites dedicated to one-off or batch production of precision machine components. When combined with CNC’s programming language referred to as G-Code to direct essential machining functions, the end result is a high-quality part. From the initial design phase, to final output, the following software utilities are standard protocol and used by almost every machine shop. Because of their importance, APM would like to provide a primer; Here is a brief look.

CAD Software

The CNC milling and machining workflow process begins with the implementation of Computer-Aided Design (CAD) software technology that allows for a 2D or 3D model rendering of a part to be manufactured. CAD allows CNC machinists and machine shop customers to digitally create, modify, analyze, and optimize the design of any component before actual milling and machining work takes place. The precision machining process itself can be expedited as CAD software allows for a part’s materials, tolerances, and dimensions to be analyzed in advance. Diagrams and drawings, or even solid models using 3D printing technology, can be viewed and modified prior to production.

CAM Software

Once a part is mocked-up with a CAD rendering, it now enters the toolpath and CNC machine programming phase. Computer-Aided Manufacturing (CAM) software is now utilized to better organize the CNC machining process. In simple terms, CAM takes the geometric models produced by CAD software and generates a series of codes (g-codes) that are fed into the control software on CNC mills and CNC lathes for example. Machinists rely on CAM utilities to form machining strategies enabling workflow efficiency. Selection of stock, dimensions, tool designation, speed and feed settings, and streamlined tool paths can all be programmed into CNC machining centers. CAM works in conjunction with CAD to achieve the desired precision part results.

Simulation and Verification Software 

When code is converted in the CAD to CAM process, errors may present themselves in precision machining operations. This is not a good thing! Modern machine tools are complex, and programming errors can result in damage to expensive equipment, wasted bar stock, and loss of time, money and productivity. Simulation and verification software is used to better write, analyze, and improve functions before milling and machining begins. Code simulators and verification programs provide a good graphic replication of how a CNC machine will perform, and what will be produced.

CNC Machine Control and Other Utility Software

 Modern CNC machines consist in part of the machine tool assembly itself, and its computer numerical control system, with control software acting as the heart of the system. Most CNC machine centers, including APM’s new Hyundai multi-axis CNC turning center, rely on OEM software built into the machine that converts CAM programming into the motions of precision machining. PC-based software also exists that allows for a desktop computer to act as a control unit, although this is more common among hobbyists. Utility packages work in conjunction with control software to monitor performance, output, and capabilities such as part feed and speed. 

Want to learn more about  modern milling and machining software, or to put its power to use for your next precision manufacturing project, contact the expert CNC machinists at APM’s Colorado machine shop today.

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont , or connect with us on LinkedIn.

About Advanced Precision Machining

APM provides comprehensive manufacturing services; from blueprint and prototyping, to machining and inspection. In their state-of-the-art machine shop, fully certified CNC machinists offer a full range of services featuring the latest CNC mills and CNC lathes to cut steels, composites, aluminum, plastics, and exotic metals. For additional information or to request a quote, please visit our website or call 303-776-1910.

Despite recent economic conditions, the challenges faced from the ongoing COVID-19 pandemic, and ongoing supply chain issues, this year is still delivering increasing demand for Advanced Precision Machining’s milling and machining services. We’re continuing with expansion, steady sales, net profit, and investment in cutting-edge technology to broaden our range of precision manufacturing offerings. Now that our Colorado machine shop is well into the first quarter of what, by early indications, promises to be another year of continued success, we are well aware of the uncertainties that still lie ahead, but we remain confident and positive as we operate in a “new” normal.

As business conditions inevitably improve, and the manufacturing economy continues to rebound from any damage the virus has dealt, all aspects of APM’s machine shop are experiencing growth. Owing to the hard work of our CNC machinists, our committed customer base, and ongoing demand for the precision parts we manufacture locally, we are still in the midst of an unprecedented period in our company’s development.

2022 is already shaping up to be another positive one for our balance sheet, and the need for our CNC milling, grinding, turning, and surface finishing services continues to be on the upswing. We’re always looking forward, and we’re optimistic about plans for future facility expansion and additional capital expenditure in new CNC machining equipment. This will allow us to further improve upon efficiency and lower costs. In fact, late last year, APM upgraded its commitment to part accuracy and precision with the purchase of a new coordinate measuring machine (CMM); We’ve added a Hyundai WIA multi-axis turning center into our lineup, and in February, we acquired a Keyence MD-X2520A multi-axis, hybrid, laser marking unit and will adding laser marking to our machine shop services.

Currently however, we have more pressing concerns that are consuming our focus given today’s labor market. Any thoughts of expanding APM’s machine shop footprint, or investing in new big ticket equipment, is quickly tempered by one factor; The human factor. There are currently certain economic realities faced by the precision machining sector, and for that matter, the manufacturing industry as a whole. When work orders increase and operations reach capacity, it doesn’t matter how many or what types of machines you possess if you don’t have the necessary personnel to operate them.

Machine shops today are still facing a familiar reality; a lack of qualified labor. Finding experienced CNC machinists has proven difficult for many shops including APM. To combat this “skills gap”, as it has been coined, there has been a resurgence in apprenticeships, community and technical college curriculums, and vocational school training, all offering machinist instruction and on the job training. The good news is that our staffing levels are adequate, and the labor market is improving, but we are still in need of a few good men or women to realize our full potential, meet increased demand, and move forward on plans for future expansion and growth.

To this end, we are currently accepting applications for a highly skilled journeyman machinist and another good machinist who will both be trained up by co-workers and management. Here is a list of qualifications and benefits…Come join the APM team!

What we’re looking for:

We’re looking to add exceptional CNC machinists to our team of top performers. Training is provided in all aspects of the machine shop environment for suitable candidates. Our culture is innovative, fast-paced, and continually improving. Ideal candidates will need an enterprising mindset with substantial experience in starting up and carrying out milling and machining projects. The successful applicant will need the ability to communicate with a sense of openness and transparency, operate with a high degree of independence, responsibility, self-sufficiency, and be able to balance best practices with a willingness to explore better ways of performing tasks. We’re growing rapidly and are moving quickly to hire well-qualified, professional CNC machinists. Our ideal candidate is an open-minded team player who will fit in well. Skills that are essential to work with APM’s team include: a good attitude, an open mind towards new ways of doing things, an eagerness to learn new skills, ease to work with, and a willingness to help in other areas of the shop.

Skills/qualifications needed:

• Preferred: 7+ years experience
• Proficiency in MasterCam CNC software and Hurco conversational programming
• Cross skills are a plus – We have multiple CNC mills and lathes
• Ability to set up required material blanks in the machine precisely as directed by programmers
• Ability to read technical drawings and retrieve dimensions for measurement, and measure parts after machining to ensure they match drawing specifications
• Ability to perform quality assurance (QA) in all aspects of machining metals and plastics
• Possess a strong understanding of inspection reporting methods/techniques
• Ability to adjust speeds and feeds to maximize production runs
• Ability to deburr parts as they are machined
• Strive to produce extremely precise parts for our customers every time
• Some physical effort required (lifting 10-50 lbs. when loading/unloading parts)
• Ideal position for an experienced, self-motivated, independent machinist

What’s in it for you:

• Benefits apply to only full-time, eligible employees
• Competitive Pay – Salary commensurate with experience ($25.00 – $35.00 per hour)
• Paychecks are received bi-weekly, or twice monthly
• Full-Time Hours
• Flexible schedule
• Clean work environment
• Friendly co-workers
• Training provided
• Half of medical premiums paid
• Paid holidays
• 2 weeks paid vacation after 1 yr. of employment

Want to learn more about our open positions, or have a question about our range of services? Contact the expert CNC machinists at APM’s Colorado machine shop for all of your milling and machining needs.

Be sure to Like us on Facebook or follow us on Twitter @APMLongmont for latest industry news and highlights from the shop.

About Advanced Precision Machining

APM provides comprehensive manufacturing services; from blueprint and prototyping, to machining and inspection. In their state-of-the-art machine shop, fully certified CNC machinists offer a full range of services featuring the latest CNC mills and CNC lathes to cut steels, composites, aluminum, plastics, and exotic metals. For additional information or to request a quote, please visit our website or call 303-776-1910.

As 2021 comes to a close, all of our fully certified CNC machinists at APM are busy as buzzing bees,  putting in long hours here at our state-of-the-art CNC machine shop. It’s been a good year for us as we’ve  taken care of new clients and established clients alike. Now, typically, we spend most of our working hours  manufacturing some of the best, most high-quality precision parts in the industry. That’s our specialty, of  course; providing milling, turning, prototype development, and production on our top-quality CNC mills and  lathes.

That being said, we also pride ourselves on taking the time and effort to provide our valued clients with the  very best customer experience we can provide. That experience includes keeping you and our other clients  updated about the latest developments in precision machining technology. It also includes letting you know  about the latest news from our shop and our newest available CNC services. (You can read all about them in our machine shop blog, too.)

Right now in Colorado (as you likely know if you live here), the cold of winter has set in, and the snows  have arrived. The trees are frozen and seemingly dead as they take their long winter’s nap. (They’ll be back  in spring, we promise!) Some of us at APM enjoy this time of year most. Others, not so much. Still, we don’t  get out in the cold, snow, and ice as often as we’d like because we’re too busy attending to our duties,  milling, and machining parts precisely for you, our clients.

As you may or may not know, the vast majority of the parts we manufacture meticulously in our shop are  fully functional from the get-go. The job is handled by our CNC mills and lathes, our top machines that are  at the forefront of what we do and demand the most attention. However, some of them need a bit more  “dressing up” before they’re ready to be shipped out. As we move into winter, we wanted to let you know  about another service that APM performs that might not take center stage, but it’s nonetheless vital to our  business; electroplating.

Here’s the thing; once we finish milling and machining a part, many believe that the production process  ends. However, that’s not always the case, as many of the parts we manufacture still need surface finishing  before they’re ready to ship. Indeed, one of the last and most crucial steps in delivering high-quality machine  parts is surface finishing so that they meet and exceed the expectations of you, our clients, and customers.  Indeed, we can’t deliver our work (or exchange any money for it) until the surface finishing is completed on many of the parts we manufacture. (The reason why is that we’re a contract machine shop.)

One of the most important of those surface finishing processes typically involves something called plating.  One of several different types of metal-finishing techniques available, plating is an excellent option for a wide variety of different parts depending on who will use them and what their purpose will be. The reason why is that plating helps a milled part to have a longer working lifespan. Plating can, for example,  increase the abrasion and wear resistance of a machined part and provide corrosion protection and lubricity. Also, plating is aesthetically pleasing and can build up the thickness of otherwise undersized parts.

What Does Plating Do for a CNC Machine Part?

Plating is the process by which a layer of new metal is attached (plated) to a CNC machined part. The metal  used for the plating can be made of tin, copper, zinc, gold, nickel, or silver. Whatever the new metal, the  plating process helps it adhere exceptionally tightly to the milled part. So tightly, in fact, that the new layer  of metal becomes fully bonded to the machined part’s surface. Typically, plating is performed using an  electrical current, which is why many of the plating processes today are known as electroplating. 

Here in our custom machine shop, the electroplating process involves immersing a milled or lathed part into  a water bath. That bath contains the plating metal (in ion form) that will be used, suspended in a chemical  solution. If it’s copper, for example, the chemical solution in the bath will be copper sulfate.

The electroplating process itself is when an electrical current is passed through the water bath containing the  chemical solution and the metal that’s being used to plate the part. Two electrodes are dipped into the water  bath, forming a battery or other power supply circuit. The part that is being plated becomes the cathode and, when it does, the metal ions in the water bath are attracted to it and form a thin player on top of it. This is called electrodeposition.

Here at APM, our state-of-the-art machine shop offers a wide variety of different electroplating techniques,  including anodizing, passivating, nickel plating and chromating

In short, an important thing to remember is that, after a part is finished being milled or lathed, one last  critical step to add functionality to that part is to electroplate it. Not only does it make the part more functional but also more attractive as well.

At APM, our goal as CNC machinists is to see your job through from start to finish and provide you with  the highest quality electroplated parts on the market. If you have questions or want to learn about our many  options for electroplating, we’re always available to take your questions and provide the answer you need.

Call or contact us today for the answers you seek. For additional information or to request a quote, please  visit http://advancedprecisionmachine.com or call 303-776-1910. Also, please follow our social media pages for more highlights from our standout shop, including Facebook, Twitter @APMLongmont, and the Advanced Precision Machining LinkedIn Company Page.