Machine Tools: Specification, Purchase, and Installation

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Machine Tools: Specification, Purchase, and Installation

Machine Tools: Specification, Purchase, and Installation

Authors: Russell Gamblin

Published: December 2013

eISBN: 9780071812238 0071812237 | ISBN: 9780071812221

Cover

About the Author

Title Page

Copyright Page

Contents

Preface

Chapter 1: Budget Phase

1.1. Attend One of the Many Quality International Trade Shows

1.2. Develop a Return on Investment Projection

1.3. Prepare a Payback Projection for the Project

1.4. Develop a Breakeven Cost for the Machine Tool

1.5. Develop the First Specification of the Machine Tool

1.6. Develop a List of Technical Differences between the Proposed Machine Tool and the Older Machines in Your Factory

1.7. Develop a List of Suppliers

1.8. Rate Machine Tool Suppliers, Their Equipment, and Their Capabilities

1.9. Visit Machine Tool Manufacturers

1.10. Gather “Ballpark” Quotes from Each Machine Tool Manufacturer

1.11. Develop an Overall Budget Cost for the Machine Tool

1.12. Develop a Budget for the Machine Tool Foundation

1.13. Develop an Electrical Cost of the Machine Tool

1.14. Develop a Facility Modification Budget for the Machine Tool

1.15. Develop a Removal and Demolition Cost for the Old Machine Tool and Its Foundation

1.16. Develop a Tooling Cost for the New Machine Tool

1.17. Final Budget Costs

1.18. Create the Overall Project Schedule

1.19. Capital Appropriation and Level of Authority

1.20. Summary

Chapter 2: Procurement

2.1. Prespecification Meeting

2.2. Machine Tool Project Specification Document

2.3. Selection of the Project Leader for the Entire Project except the Foundation

2.4. Machine Tool Supplier Visits and Quotes

2.5. Machine Tool Supplier References

2.6. The Final Approved Machine Tool Specification

2.7. Checklist for the Project Leader/Manager during the Procurement Phase

2.8. Operator Training

2.9. Maintenance and Facilities Training

2.10. Application and Programming Training

2.11. Schedule for the Machine Tool Build

2.12. Terms and Conditions

20 Percent Down with Receipt of the Buyer’s Purchase Order

30 Percent with Sign-Off at the Machine Tool Supplier’s Factory

30 Percent with the Acceptance of the Machine Tool at the Buyer’s Facility

20 Percent Four Weeks after Acceptance of the Machine Tool at the Buyer’s Factory

2.13. Liquidated Damages due to Late Delivery

2.14. Consequential Damages

2.15. Ordering the Machine Tool

2.16. Visit the Supplier’s Factory during the Build Process of Your Machine Tool

2.17. Acceptance of the Machine Tool at the Supplier’s Facility

2.18. Summary

Chapter 3: Layout Phase

3.1. Layout during the Procurement Phase

3.2. Maximize Floor Space

3.3. General Notes for Layout of a Horizontal Boring Machine

3.4. Maximum Weight of the Largest Piece of the Machine Tool

3.5. Soil Boring Specification

3.6. Minimum Requirements for the Machine Tool Location

3.7. Develop the Overall Schedule of the Foundation Installation

3.8. Planning the Removal of the Existing Equipment

3.9. Planning the Demolition of the Old Foundation and/or Floor Slabs around the Old Machine Tool

3.10. Planning the Removal of the Old Utilities (Water, Power, Air, etc.)

3.11. Floor Plate Layout and Installation

3.12. Summary

Chapter 4: Foundation Phase

4.1. Prefoundation Meeting and Foundation Project Leader

4.2. Schedule for the Completed Foundation

4.3. Tricks of the Trade (Trench Design and Saving Floor Space)

4.4. Bury the Conduit and Black Iron Pipe in the New Foundation Only

4.5. Foundation Pit Modifications

4.6. Develop a Foundation Design Specification

4.7. At Least Five Review Sessions for the Foundation Design

4.8. Bid Foundation Design and Purchase Order for the Foundation Design

4.9. Installation of the Dust Walls and Limiting Access during Construction

4.10. Purchase Order for the Demolition of the Old Foundation and Installation of the New Foundation

4.11. Review and Sign-off on the Rebar Drawings for the New Foundation

4.12. Prejob Safety Briefing prior to Demolition and the Installation of the New Foundation

4.13. Concrete Cylinder Test

4.14. Foundation Cure Period

4.15. General Contractor Specification

4.16. Foundation Summary

Chapter 5: Installation Phase

5.1. Create the Machine Tool Installation Specification

5.2. Installation of the Machine Tool without Maintenance and Facility Support

5.3. Machine Tool Installation Bid—Get at Least Three Quotes

5.4. Machine Tool Installation Purchase Order

5.5. Purchase of the Machine Tool Lubrication Oils and Coolant

5.6. Epoxy Painting of the Nonshrink Grout and Concrete Foundation

5.7. Purchase and Installation of the Machine Tool Metal Chip Bin

5.8. Purchase and Installation of the Grout Cans, Grout Forms, and Grout Pour

5.9. Purchase and Installation of the Safety Rails of the Machine Tool

5.10. Overall Installation Schedule

5.11. General Notes for Installation of the Machine Tool

5.12. Installation of the Ladders and Stairs to Access the Foundation Pits

5.13. Summary

Chapter 6: Preparation Phase

6.1. Preparation Phase

6.2. Chip Conveyor Requirements When the Chip Conveyor Is Supplied by the OEM

6.3. Chip Conveyor Requirements When the Chip Conveyor Is Not Supplied by the OEM

6.4. Chip Deflectors for the Chip Conveyor and Other Sections of the Machine Tool

6.5. Main Power Source for the Machine Tool

6.6. Secondary Power Source for the Machine Tool

6.7. Compressed Air

6.8. Water

6.9. Chilled Water

6.10. Coolant/Oil Skimmers

6.11. Coolant Coalescer

6.12. Coolant Wall and Enclosure

6.13. Touching Up the Epoxy Coating of the Foundation

6.14. Lighting in the Foundation Pits

6.15. Isolation Transformer

6.16. DNC Software

6.17. Direct Numerical Control Procedure

6.18. PC at the Machine Tool for Network Connection

6.19. Main 480-VAC Breaker

6.20. Deck Plate, Checkered Plate, and Bar Grating around the Machine Tool Covering the Machine Tool Foundation Pits

6.21. Laser Alignment Checks

6.22. Final Machine Tool Acceptance

6.23. Machining Test

6.24. Develop and Test a Part Program

6.25. Teleservice Provided by the Machine Tool OEM and Installed and Tested by the Machine Tool Buyer

6.26. Warranty

6.27. Conduit (EMT, IMC, Rigid, and PVC) Required for the Machine Tool

6.28. Power Track or Wireway

6.29. Head Attachments (Head House or No Head House)

6.30. Sag Compensation

6.31. Temperature Compensation

6.32. Checking of the Hard and Soft Overtravel Switches of the Machine Tool

6.33. Basic Reference of the Machine Tool

6.34. Start-Up of the Machine Tool from an Off State

6.35. Lock Out and Tag Out Procedures and Disconnect for the Machine Tool

6.36. Backup of All the CNC Data

6.37. Viewing Of and Access To the PLC Ladder Logic

6.38. Summary

Chapter 7: Start-up Phase

7.1. Start-up Phase

7.2. Machining Test and Test Parts

7.3. Acceptance Tests

7.4. Final Machining Test

7.5. Continuous Running Test

7.6. Uptime Accountability of the Machine Tool

7.7. Machine Tool Supplier Support during the First Year

7.8. One-Year Meeting after Final Acceptance—Lessons Learned

7.9. Documentation of the Machine Tool

7.10. Summary

Chapter 8: Maintenance Phase

8.1. Why Perform Maintenance?

8.2. Decrease Machining Downtime by Implementing a Daily Operational and Preventive Maintenance Program

8.3. Increase Overall Productivity of the Machine Tool

8.4. Higher Accuracy and Quality of Parts Produced by Checking Your Machine Tool’s Alignments and Laser Calibration at least Once per Year

8.5. Daily Operations Checklist

8.6. Monthly Maintenance Checklist

8.7. Semiannual Maintenance Checklist

8.8. Annual Maintenance Checklist

8.9. Standard Spare Parts List

8.10. Long-Term Spare Parts List

8.11. Summary

Final Summary of the Book

Index