3D Model Lifecycle of Money
"Money doesn't grow on trees" i.e. money isn't free, is pretty widely accepted - a business has to sell services or goods to make money. Perhaps not so obvious is that, in a business, money has a lifecycle and that lifecycle costs money.
Let's look at a generic company that operates entirely off of its cash flow and doesn't use credit for day to day operations. A simplified money lifecycle might look something like the following where:
'F' = funds (postage, shipping, etc)
'L' = labor
'M' = materials (forms, boxes, etc.)
'T' = time
Lifecycle Start
1. Get Money
a. Customer Purchase Order Processing
1. Receive PO (L, T)
2. Issue Shop Orders (L, M, T)
b. Fulfillment
1. Pull Inventory (L, M, T)
2. Box and Ship (F, L, M, T)
c. Customer Invoicing
1. Create and Send Invoices (F, L, M, T)
2. Wait for Payment (T)
d. Customer Payment Processing
1. Receive and Process Payments (L, M, T)
2. Reconcile Delinquent Accounts (F, L, M, T)
2. Keep Money (for some time period) (T)
3. Spend Money
a. Purchase Order Processing
1. Generate Purchase Requisition (L, M, T)
2. Create and Send Purchase Orders (F, L, M, T)
b. Receive Goods
1. Receive and Reconcile Shipments (L, M, T)
2. Receiving Inspection (L, M, T)
c. Invoice Processing
1. Receive and Reconcile Invoices (L, T)
2. Issue Payment Request (L, M, T)
d. Payment Processing
1. Generate and Send Payments (F, L, M, T)
2. Reconcile Accounts (L, M, T)
Lifecyle End
If F, L, M and T all cost money, then the value of a dollar on a customer's PO is significantly reduced by the time it's spent i.e. when its lifecycle has ended. If a company only has one product and one customer, then the reduction in value may be fairly constant. However, if a company has multiple products and/or multiple customers, it is very unlikely that the cost will be constant.
Costs that vary by product or customer are not "overhead". If a company fails to understand the different costs, the company has no hope of maximizing its profit, it will invariably create undesirable price customer combinations. Customers being charged too much may leave. Customers being charged too little may bleed the company dry.
Friday, September 30, 2011
Sunday, September 18, 2011
3D Model FANUC Program Transfer
3D Model FANUC Program Transfer
FANUC's Program Transfer Tool does a great job on CNC programs and offsets, but not so great on CNC control parameters. Download and install Fanuc2Numbers to convert parameters like "[26312*65536+46138]/[67108864*32]" into ordinary numbers like "0.80300".
1. Use the Program Transfer Tool to download the control's parameter file to a PC.
2. Start Fanuc2Numbers and "Agree" not to hold me responsible if something goes wrong.
3. Select the "Fanuc" button and browse to the parameter file you downloaded.
4. Select the "New" button and enter a filename for the converted parameters. If you use the same name, it will over write the original file.
5. Select the "Convert" button and you're done. The new file will contain only ordinary numbers.
FANUC's Program Transfer Tool does a great job on CNC programs and offsets, but not so great on CNC control parameters. Download and install Fanuc2Numbers to convert parameters like "[26312*65536+46138]/[67108864*32]" into ordinary numbers like "0.80300".
1. Use the Program Transfer Tool to download the control's parameter file to a PC.
2. Start Fanuc2Numbers and "Agree" not to hold me responsible if something goes wrong.
3. Select the "Fanuc" button and browse to the parameter file you downloaded.
4. Select the "New" button and enter a filename for the converted parameters. If you use the same name, it will over write the original file.
5. Select the "Convert" button and you're done. The new file will contain only ordinary numbers.
Wednesday, September 7, 2011
3D Model Scanner Resolution vs Feature Size
3D Model Scanner Resolution vs Feature Size
The size of a feature that can be reliably detected by a laser scanner is significantly larger than the scanner’s resolution.
A scanner’s resolution or point density is a measure of how closely points are spaced on the surfaces being scanned. A scanner with a resolution of 50µ (.050mm) will record a point every 50µ if the scanner is perpendicular to the surface being scanned. As it is not generally possible to always scan perpendicular to all surfaces, the scan angle should be taken into account. For instance, at an angle of 45 degrees, the distance between points increases to approximately 71µ. Once the point spacing is known, detectible feature size can be calculated.
The laser never captures 100% of any feature and the closer the point density is to the size of the feature, the lower the percentage of capture. A 1mm feature scanned with 70µ point spacing can be detected to 93% and a 0.5mm feature to 86%. Conversely, the size of the feature can be calculated. For an 80% capture with 70µ point spacing, the feature must be at least 0.35mm.
The size of a feature that can be reliably detected by a laser scanner is significantly larger than the scanner’s resolution.
A scanner’s resolution or point density is a measure of how closely points are spaced on the surfaces being scanned. A scanner with a resolution of 50µ (.050mm) will record a point every 50µ if the scanner is perpendicular to the surface being scanned. As it is not generally possible to always scan perpendicular to all surfaces, the scan angle should be taken into account. For instance, at an angle of 45 degrees, the distance between points increases to approximately 71µ. Once the point spacing is known, detectible feature size can be calculated.
The laser never captures 100% of any feature and the closer the point density is to the size of the feature, the lower the percentage of capture. A 1mm feature scanned with 70µ point spacing can be detected to 93% and a 0.5mm feature to 86%. Conversely, the size of the feature can be calculated. For an 80% capture with 70µ point spacing, the feature must be at least 0.35mm.
Saturday, August 13, 2011
3D Model New SolidWorks User
3D Model New SolidWorks User
A new client requires that I supply all CAD files in SolidWorks with intact feature trees. The project is large enough that it warranted purchasing a seat. The project's schedule is fairly aggressive and I had to come up to speed with the new software as quickly as possible.
I plowed through a couple of tutorials and went to work on my client's project. Although certainly not a power user, I am able create relatively complex geometry and assembly constraints with little fumbling.
The interface and workflow are very similar to Rapidform XOR, which is my primary CAD modeling tool. Rapidform has extensive tools for working with meshes and point clouds and for reverse engineering. And it will continue to be Reverse Austin's primary CAD package, but I'm very impressed with the functionality and ease of use of SolidWorks.
A new client requires that I supply all CAD files in SolidWorks with intact feature trees. The project is large enough that it warranted purchasing a seat. The project's schedule is fairly aggressive and I had to come up to speed with the new software as quickly as possible.
I plowed through a couple of tutorials and went to work on my client's project. Although certainly not a power user, I am able create relatively complex geometry and assembly constraints with little fumbling.
The interface and workflow are very similar to Rapidform XOR, which is my primary CAD modeling tool. Rapidform has extensive tools for working with meshes and point clouds and for reverse engineering. And it will continue to be Reverse Austin's primary CAD package, but I'm very impressed with the functionality and ease of use of SolidWorks.
Friday, July 8, 2011
3D Model - When Calibration is a Bad Thing
3D Model - When Calibration is a Bad Thing
Equipment and instrument calibration is not an acceptable substitute for process feedback.
I once worked with a very intelligent Quality Assurance (QA) engineer. In a discussion where he was espousing the virtues of mandatory periodic equipment calibrations, he made the statement "I never buy tires from a company that doesn't provide alignment services. I always have my car alignment checked when I buy new tires." He was quite certain that this analogy supported his argument that periodic equipment and instrument calibrations were essential.
The concept argued by the QA engineer is that all things that may require adjustment or calibration have to be checked and adjusted on a periodic basis by qualified technicians using specialized equipment. Belief in this concept is ubiquitous in today's QC systems and is even dictated by many regulatory bodies including the United States FDA.
Back to the car analogy: Let’s suppose that I'm taking my car in to get new tires after having gotten 60,000 miles on my old ones. Further, let's say that the tires all wore evenly, that the car drives straight and true and that the car's gas mileage has been constant and is acceptable. Should I have someone check and adjust the wheel alignment?
The purpose of wheel alignment is to insure that the tires track true to the vehicle's path so that the car drives straight, the tires wear evenly, the tires last a long time and the vehicle gets good gas mileage. If these conditions are true, why let someone adjust the alignment? No matter how well trained and no matter how specific their equipment, they are not going to make things any better and they might make things worse. If these conditions are not true, why did I wait until now to do something about it?
A successful process requires timely feedback. Waiting until my tires are worn out to check my alignment is not timely. I should visually inspect my tires as I walk up to the car, not only for wear, but for proper inflation. When I drive, I should be aware of unusual or unacceptable behavior like pulling or drifting. And when I fill up at the gas pump, I should check my gas mileage to verify that nothing’s amiss with the engine or drive train.
Time and time again, I've seen processes go haywire after mandatory equipment calibrations. I’ve also seen "validated" processes, using calibrated equipment, drift out of specification. Measurement processes are especially vulnerable. It's common to see measurement processes go unmonitored and reliant solely on periodic calibrations.
Do not rely on equipment calibrations to insure process integrity. Find timely feedback mechanisms and use them to monitor processes. Use calibrations as diagnostic tools, not as process controls.
Equipment and instrument calibration is not an acceptable substitute for process feedback.
I once worked with a very intelligent Quality Assurance (QA) engineer. In a discussion where he was espousing the virtues of mandatory periodic equipment calibrations, he made the statement "I never buy tires from a company that doesn't provide alignment services. I always have my car alignment checked when I buy new tires." He was quite certain that this analogy supported his argument that periodic equipment and instrument calibrations were essential.
The concept argued by the QA engineer is that all things that may require adjustment or calibration have to be checked and adjusted on a periodic basis by qualified technicians using specialized equipment. Belief in this concept is ubiquitous in today's QC systems and is even dictated by many regulatory bodies including the United States FDA.
Back to the car analogy: Let’s suppose that I'm taking my car in to get new tires after having gotten 60,000 miles on my old ones. Further, let's say that the tires all wore evenly, that the car drives straight and true and that the car's gas mileage has been constant and is acceptable. Should I have someone check and adjust the wheel alignment?
The purpose of wheel alignment is to insure that the tires track true to the vehicle's path so that the car drives straight, the tires wear evenly, the tires last a long time and the vehicle gets good gas mileage. If these conditions are true, why let someone adjust the alignment? No matter how well trained and no matter how specific their equipment, they are not going to make things any better and they might make things worse. If these conditions are not true, why did I wait until now to do something about it?
A successful process requires timely feedback. Waiting until my tires are worn out to check my alignment is not timely. I should visually inspect my tires as I walk up to the car, not only for wear, but for proper inflation. When I drive, I should be aware of unusual or unacceptable behavior like pulling or drifting. And when I fill up at the gas pump, I should check my gas mileage to verify that nothing’s amiss with the engine or drive train.
Time and time again, I've seen processes go haywire after mandatory equipment calibrations. I’ve also seen "validated" processes, using calibrated equipment, drift out of specification. Measurement processes are especially vulnerable. It's common to see measurement processes go unmonitored and reliant solely on periodic calibrations.
Do not rely on equipment calibrations to insure process integrity. Find timely feedback mechanisms and use them to monitor processes. Use calibrations as diagnostic tools, not as process controls.
Saturday, June 25, 2011
3D Model Overmold Scanning
3D Model Overmold Scanning
3D Scanning can be a very powerful tool for correcting overmold problems.
Flash and/or failure to shut off in overmolding is often caused by a poor fit between the part and the mold. Scanning can provide an easy and straightforward method to correct the fit.
The part to be overmolded is scanned and enough data is collected to accurately describe the part. Software such as Rapidform is used to create a solid model (CAD model) of the part including all the shrinkage, warpage, etc. The end result being a CAD model that accurately represents the part to be overmolded. The model is then used to redesign and modify the overmold tooling to fit the part precisely.
3D Scanning can be a very powerful tool for correcting overmold problems.
Flash and/or failure to shut off in overmolding is often caused by a poor fit between the part and the mold. Scanning can provide an easy and straightforward method to correct the fit.
The part to be overmolded is scanned and enough data is collected to accurately describe the part. Software such as Rapidform is used to create a solid model (CAD model) of the part including all the shrinkage, warpage, etc. The end result being a CAD model that accurately represents the part to be overmolded. The model is then used to redesign and modify the overmold tooling to fit the part precisely.
Tuesday, June 7, 2011
3D Model Dimensional Inspection
3D Model Dimensional Inspection
X-ray CT scanning and 3D Laser scanning are ideal for dimensional inspection of components, especially when ergonomic or freeform shapes are involved.
Modern CAD software is not limited to prismatic features. Designers are able to incorporate a wide variety of shapes that often defy inspection without the use of scanning. This is especially true with injection molded components.
When diagnosing overmolding problems or assembly issues on parts with complex surfaces, scanning is often the only way to collect enough data to accurately characterize the components and find the problems. Sometimes it's even beneficial to "reverse engineer" the molded component and create a solid model (CAD model) with shrinks, checks, warps, etc intact.
X-ray CT scanning and 3D Laser scanning are ideal for dimensional inspection of components, especially when ergonomic or freeform shapes are involved.
Modern CAD software is not limited to prismatic features. Designers are able to incorporate a wide variety of shapes that often defy inspection without the use of scanning. This is especially true with injection molded components.
When diagnosing overmolding problems or assembly issues on parts with complex surfaces, scanning is often the only way to collect enough data to accurately characterize the components and find the problems. Sometimes it's even beneficial to "reverse engineer" the molded component and create a solid model (CAD model) with shrinks, checks, warps, etc intact.
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