Hi Ash,
As I looked at your pictures I thought of how I find hole centers when the indicator is not big enough to touch all sides. With large parts I find I have to rotate, or "sweep", the indicator at each position to get the highest reading on the dial. This eliminates errors in trying to align the needle to a specific angle.
You are correct when you say the skill of the machinist has a direct impact on set-up time. The only method I have found to correct this is to create a check list of steps needed to find the center of the part, and then have one-on-one training with those who can't do it in a timely manner. If the trainee questions the check list, first ask yourself if the question is valid. If so, the check list needs to be revised. If not, you have to find the best method to communicate with the trainee until he/she understands what needs to be done to complete the task in a profitable manner. Deviating from a proven check list should not be allowed.
Skilled labor cannot be replaced cheaply. You can invest a lot of time trying to create an automatic machine function, and you may succeed, or you can invest time in training the workers. Either way, you will have to invest something into the process.
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Later,
Charlie |