I worked as technical staff in the machine shop which produces over 15,000 parts a day. My main project involved introducing two new machines that completely changed the way tractor clutch housings were machined. I drew over 200 tools on the 3D CAD/CAM software, Opus, and wrote the CNC programs. I created setup sheets, using Opus to identify which tools were used on which machines. I wrote all the routing and tooling BOM’s (Bill of Materials) using SAP enterprise software. Daily jobs consisted of looking after the SPC (Statistical Process Control) system on each line, keeping production drawings up to date and making alterations to tooling BOM’s. Some of the hardware and software I learnt to use at Luk includes: CNC Machines (Chiron, Emag, Weisser, Hwachen), Kelch – shadowgraph pre setter, Opus CAD/CAM and SAP enterprise.
I project manage up to 60 new clutches at any one time with the normal lead-time for one new clutch being 12 weeks. I have set up a process checklist to ensure that everything is arranged on time and deadlines are met. To help organize all the different departments involved and to discuss what stage the process is at, I organize bi-weekly meetings. I create an FMEA variant for each new clutch to ensure correct manufacture with no defects. I have restored a Gildemeister CNC turning machine back to operating condition. The machine is a vital point in the production line but unfortunately was neglected until it was unusable. Starting from scratch, I ordered all new tooling as well as rewrote the CNC programs using Opus CAD/CAM software. This has reduced cycles times and a large cost saving has been made on expensive CBN grade inserts.I am also responsible for the day-to-day technical problems that range from tooling, supplier and quality problems.