18

November
2015

Manufactuing and Engineering Technology Expo to debunk the myth of manufacturing jobs

Written by OSG


What is the first thought that comes to your mind when you think of manufacturing jobs? Some of you probably imagine a dirty shop floor and oily, noisy machines. Sadly, this is what most of the people think of manufacturing. However, the College of DuPage (COD) in Glen Ellyn, Illinois has been trying to debunk this myth about manufacturing by showing interested students what manufacturing really is. As part of this effort, COD hosted their 4th annual Manufacturing and Engineering Technology Expo last week at their Technical Education Center (TEC).


Over 200 students from 9 local high schools visited the expo and interacted with 15 vendors who came prepared to provide information about their businesses and discuss potential career paths. The students also received a tour of the beautiful machine shop at the TEC.


As we continue to embrace the mission behind MfgDay which is to inspire the next generation of manufacturers, OSG volunteered to participate in the COD expo as a vendor and talked to the students about our company, available career paths and internship opportunities. OSG district sales manager, Matt Dahlberg, also shared his experiences from his career. Matt graduated from Technology Center of DuPage and started in manufacturing as an apprentice at a local die mold company. Over the past 13 years, Matt progressed in his career to CNC machinist, CNC machine programmer, then CAD/CAM designer and most recently to OSG district manager. In his present position, Matt applies his years of manufacturing shop floor experience to help his customers cost effectively and efficiently manufacture their parts with OSG drills, taps, end mills, indexable cutting tools and thread forming die products.

   

Nowadays, most high schools encourage and prepare students to attend 4-year-colleges after graduation. Fenton High School in Bensenville, Illinois also focuses on sending students to 4-year-colleges, but the technical education teacher, Ben Nelson, decided to take his students to this year’s expo. “I want to make my students realize the variety of career paths available to them,” said Nelson. “Matt’s career path is eye opening for kids because average kids do not know such a career path is actually possible.”


On the other hand, the technology and engineering program at Lake Park High School in Roselle, Illinois focuses more on developing students’ practical skills. Andy Rupnick, technology and engineering teacher at Lake Park High School said, “We are pushing career readiness.” The school has just opened a new innovation center which houses 10 brand new manufacturing machines. The new facility is used to accommodate 5 sections of classes in manufacturing and 4 sections of classes in engineering. Rupnick said he has a large number of students who are interested in a manufacturing career.


Associate Professor of Manufacturing Technology at COD, Jim Filipek, taught a class during the expo that shared with students the advantages and disadvantages of a manufacturing career. He said it is important for us to be honest with the students and to tell them how manufacturing jobs really are.


“A manufacturing career is not glamorous, and you do not dress up to go to work,” said Filipek, “but it gives you job security with a thick wallet which replaces being glamorous.”


OSG wants to help change the stereotype of manufacturing as a dirty shop floor environment and to share the rewarding job opportunities available to today’s students through our involvement in the community and with these technical school programs. In order to be successful, we understand that manufacturers share the responsibility with educators to inspire students to consider and pursue manufacturing careers. In the long run, this is essential to the future of American manufacturing.  

 

 


11

November
2015

Case Study: Down time is the time to improve efficiency and productivity

Written by OSG


Current Situation


David Whitmire, OSG district manager, has been covering a sales territory in Texas and Oklahoma for 9 years. He has witnessed both the best and worst days of the energy industry. Since the price of oil per barrel has recently reached record lows, our economy and oil field manufacturers have been severely affected. An increasing number of layoffs and downsizing at companies has occurred in the area. During this down time, some oil field manufacturers started to do their homework by reconsidering their machining processes as an avenue to cut costs. This has opened up some new opportunities for OSG in David’s territory.


One of David’s customers is a large pump housing manufacturer in the oil field industry. During the industry slowdown, the company wanted to be proactive, so they invited OSG and a local distributor to host a tap trouble shooting seminar. During the seminar, David showed them the OSG EXOTAP® A-Tap® and EXOPRO® Mega Muscle® drill videos. These videos drew a lot of attention as they showed A-Tap® and Mega Muscle® products surpassing speeds and feeds of competitors’ tools. This company produces 50 to 60 parts after spending over 625 hours machining per month. David decided to perform tool testing with his local distributor to help the company improve productivity and cut costs.


Tool Testing/Solutions


Material: 4140 Modified Alloy Steel


1. ¾-10 EXOTAP® A-Tap® (18 SFM) vs. Competitor A’s tap (18 SFM)


2.
1 ¼-7 HY-PRO® VXL Tap (30 SFM and 13.1486 IPM) vs. Competitor A’s tap (23 SFM and 11.0 IPM)


3.
1 ½-6 HY-PRO® VXL Tap (30 SFM and 12.5 IPM) vs. Competitor A’s tap (23 SFM and 10.0 IPM)


4.
½-13 EXOTAP® A-Tap® 50 SFM and 29.3758 IPM vs. Competitor A’s tap (13 SFM and 7.692 IPM)


5.
7/16” EXOPRO® Mega Muscle® Drill (325 SFM and 48.2 IPM) vs. Competitor B’s Cam Drill (8.2 IPM)


6.
7/15” EXOCARB® WDO® Drill (325 SFM and 28.4 IPM) vs. Competitor B’s Cam Drill (2.5 IPM)


7.
22mm PHOENIX® PXD Exchangeable Head Drill 300 (SFM and 21.2 IPM) vs. Competitor B’s Cam Drill (2.8 IPM)


Results


Test 1 demonstrated a significant advantage of the A-Tap®. Even if it ran at the same speeds and feeds with the competitor’s tap, the A-Tap® was able to produce 25% to 40% more pump housings and to reduce costs by $22 per tool versus the competitor’s tap.


Tests 2, 3, 4 and 5 showed that OSG’s taps and drills ran at faster speeds than the competitors’ tools, and the A-Tap®, VXL Tap and Mega Muscle® products were able to reduce the cycle time by 23 minutes. In addition, the A-Tap® and Mega Muscle® machined 5 times more parts than the competitors’ tools did.


Tests 6 and 7 have not been completed, but David is confident that the WDO® drills and PXD drills will reduce the cycle times even more. By using OSG’s taps and drills in their operation, David predicts that the company will be able to reduce at least 21 hours of machining time per month!




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