Table of Contents
Preface xiii
1 Budget Phase 1
1.1 Attend One of the Many Quality International Trade Shows 3
1.2 Develop a Return on Investment Projection 4
1.3 Prepare a Payback Projection for the Project 5
1.4 Develop a Breakeven Cost for the Machine Tool 5
1.5 Develop the First Specification of the Machine Tool 6
1.6 Develop a List of Technical Differences between the Proposed Machine Tool and the Older Machines in Your Factory 13
1.7 Develop a List of Suppliers 13
1.8 Rate Machine Tool Suppliers, Their Equipment, and Their Capabilities 14
1.9 Visit Machine Tool Manufacturers 17
1.10 Gather "Ballpark" Quotes from Each Machine Tool Manufacturer 18
1.11 Develop an Overall Budget Cost for the Machine Tool 18
1.12 Develop a Budget for the Machine Tool Foundation 19
1.13 Develop an Electrical Cost of the Machine Tool 20
1.14 Develop a Facility Modification Budget for the Machine Tool 21
1.15 Develop a Removal and Demolition Cost for the Old Machine Tool and Its Foundation 22
1.16 Develop a Tooling Cost for the New Machine Tool 22
1.17 Final Budget Costs 24
1.18 Create the Overall Project Schedule 24
1.19 Capital Appropriation and Level of Authority 27
1.20 Summary 27
2 Procurement 29
2.1 Prespecification Meeting 31
2.2 Machine Tool Project Specification Document 33
2.3 Selection of the Project Leader for the Entire Project Except the Foundation 33
2.4 Machine Tool Supplier Visits and Quotes 34
2.5 Machine Tool Supplier References 36
2.6 The Final Approved Machine Tool Specification 38
2.7 Checklist for the Project Leader/Manager during the Procurement Phase 43
2.8 Operator Training 43
2.9 Maintenance and Facilities Training 43
2.10 Application and Programming Training 49
2.11 Schedule for me Machine Tool Build 49
2.12 Terms and Conditions 51
20% Down with Receipt of the Buyer's Purchase Order 53
30% with Sign-Off at the Machine Tool Supplier's Factory 53
30% with the Acceptance of the Machine Tool at the Buyer's Facility 54
20% Four Weeks after Acceptance of the Machine Tool at the Buyer's Factory 54
2.13 Liquidated Damages due to Late Delivery 54
2.14 Consequential Damages 55
2.15 Ordering the Machine Tool 55
2.16 Visit the Supplier's Factory during the Build Process of Your Machine Tool 55
2.17 Acceptance of the Machine Tool at the Supplier's Facility 56
2.18 Summary 56
3 Layout Phase 57
3.1 Layout during the Procurement Phase 59
3.2 Maximize Floor Space 61
3.3 General Notes for Layout of a Horizontal Boring Machine 63
3.4 Maximum Weight of the Largest Piece of the Machine Tool 66
3.5 Soil Boring Specification 68
3.6 Minimum Requirements for the Machine Tool Location 69
3.7 Develop the Overall Schedule of the Foundation Installation 71
3.8 Planning the Removal of the Existing Equipment 72
3.9 Planning the Demolition of the Old Foundation and/or Floor Slabs around the Old Machine Tool 73
3.10 Planning the Removal of the Old Utilities (Water, Power, Air, etc.) 74
3.11 Floor Plate Layout and Installation 75
3.12 Summary 79
4 Foundation Phase 81
4.1 Prefoundation Meeting and Foundation Project Leader 83
4.2 Schedule for the Completed Foundation 85
4.3 Tricks of the Trade (Trench Design and Saving Floor Space) 87
4.4 Bury the Conduit and Black Iron Pipe in the New Foundation Only 91
4.5 Foundation Pit Modifications 92
4.6 Develop a Foundation Design Specification 95
4.7 At Least Five Review. Sessions for the Foundation Design 97
4.8 Bid Foundation Design and Purchase Order for the Foundation Design 99
4.9 Installation of the Dust Walls and Limiting Access during Construction 99
4.10 Purchase Order for the Demolition of the Old Foundation and Installation of the New Foundation 100
4.11 Review and Sign-off on the Rebar Drawings for the New Foundation 101
4.12 Prejob Safety Briefing prior to Demolition and the Installation of the New Foundation 101
4.13 Concrete Cylinder Test 102
4.14 Foundation Cure Period 102
4.15 General Contractor Specification 103
4.16 Foundation Summary 105
5 Installation Phase 107
5.1 Create the Machine Tool Installation Specification 109
5.2 Installation of the Machine Tool without Maintenance and Facility Support 113
5.3 Machine Tool Installation Bid-Get At Least Three Quotes 114
5.4 Machine Tool Installation Purchase Order 115
5.5 Purchase of the Machine Tool Lubrication Oils and Coolant 116
5.6 Epoxy Painting of the Nonshrink Grout and Concrete Foundation 116
5.7 Purchase and Installation of the Machine Tool Metal Chip Bin 117
5.8 Purchase and Installation of the Grout Cans, Grout Forms, and Grout Pour 121
5.9 Purchase and Installation of the Safety Rails of the Machine Tool 121
5.10 Overall Installation Schedule 122
5.11 General Notes for Installation of the Machine Tool 124
5.12 Installation of the Ladders and Stairs to Access the Foundation Pits 124
5.13 Summary 124
6 Preparation Phase 125
6.1 Preparation Phase 127
6.2 Chip Conveyor Requirements When the Chip Conveyor Is Supplied by the OEM 127
6.3 Chip Conveyor Requirements When the Chip Conveyor Is Not Supplied by the OEM 128
6.4 Chip Deflectors for the Chip Conveyor and Other Sections of the Machine Tool 130
6.5 Main Power Source for the Machine Tool 130
6.6 Secondary Power Source for the Machine Tool 131
6.7 Compressed Air 131
6.8 Water 132
6.9 Chilled Water 132
6.10 Coolant/Oil Skimmers 133
6.11 Coolant Coalescer 134
6.12 Coolant Wall and Enclosure 135
6.13 Touching Up the Epoxy Coating of the Foundation 136
6.14 Lighting in the Foundation Pits 136
6.15 Isolation Transformer 137
6.16 DNC Software 137
6.17 Direct Numerical Control Procedure 139
6.18 PC at the Machine Tool for Network Connection 139
6.19 Main 480-VAC Breaker 139
6.20 Deck Plate, Checkered Plate, and Bar Grating around the Machine Tool Covering the Machine Tool Foundation Pits 140
6.21 Laser Alignment Checks 140
6.22 Final Machine Tool Acceptance 141
6.23 Machining Test 141
6.24 Develop and Test a Part Program 142
6.25 Teleservice Provided by the Machine Tool OEM and Installed and Tested by the Machine Tool Buyer 142
6.26 Warranty 142
6.27 Conduit (EMT, IMC, Rigid, and PVC) Required for the Machine Tool 143
6.28 Power Track or Wireway 145
6.29 Head Attachments (Head House or No Head House) 145
6.30 Sag Compensation 145
6.31 Temperature Compensation 146
6.32 Checking of the Hard and Soft Overtravel Switches of the Machine Tool 146
6.33 Basic Reference of the Machine Tool 147
6.34 Start-up of the Machine Tool from an Off State 147
6.35 Lock Out and Tag Out Procedures and Disconnect for the Machine Tool 148
6.36 Backup of All the CNC Data 148
6.37 Viewing Of and Access To the PLC Ladder Logic 148
6.38 Summary 149
7 Start-up Phase 151
7.1 Start-up Phase 153
7.2 Machining Test and Test Parts 153
7.3 Acceptance Tests 154
7.4 Final Machining Test 154
7.5 Continuous Running Test 154
7.6 Uptime Accountability of the Machine Tool 155
7.7 Machine Tool Supplier Support during the First Year 155
7.8 One-Year Meeting after Final Acceptance-Lessons Learned 156
7.9 Documentation of the Machine Tool 156
7.10 Summary 157
8 Maintenance Phase 159
8.1 Why Perform Maintenance? 161
8.2 Decrease Machining Downtime by Implementing a Daily Operational and Preventive Maintenance Program 161
8.3 Increase Overall Productivity of the Machine Tool 162
8.4 Higher Accuracy and Quality of Parts Produced by Checking Your Machine Tool's Alignments and Laser Calibration At Least Once per Year 163
8.5 Daily Operations Checklist 164
8.6 Monthly Maintenance Checklist 165
8.7 Semiannual Maintenance Checklist 165
8.8 Annual Maintenance Checklist 165
8.9 Standard Spare Parts List 169
8.10 Long-Term Spare Parts List 170
8.11 Summary 171
Final Summary of the Book 173
Index 181
