Smart manufacturers are continuously looking for more and better ways to reduce production costs. Faster, more precise CNC machine tools aided by robotic-based automation and pallet loading systems are proven ways to boost productivity. However, there’s more to reducing overall production costs than using the latest technologies. For optimum efficiency, manufacturers must consider all aspects of the process from part design to raw materials, machining, quality assurance and delivery to the customer.
One of the most prominent technological trends on display at IMTS 2012 had more to do with communications and process control than speeds, feeds and other mechanical specifications. While CNC machine tool OEMs continue to create better, faster and more accurate products, they also enable greater interoperability between various machines, controls and software applications by establishing shop floor networks to share data. By using XML and Internet Protocol technologies, CNC machines provide real-time data that promotes greater manufacturing efficiencies.
The federal government is taking a much closer look at how employees are classified and if employers are abiding by appropriate wage and hour laws. For manufacturing companies, a major concern is the distinction between non-exempt and exempt employees. 
The benefits of 5-axis machining are well known to many manufacturers. Unlike traditional 3- and 4-axis machines, 5-axis simultaneous machining eliminates multiple special fixtures and considerable operator time required to move parts from one machine to another and set up the parts in between machining cycles. With true 5-axis capability you can completely machine a part in one cycle, often without any special fixtures, and with no costly operator intervention.
Dealing with thermal deformation can be a time-consuming activity for the machine operator. When Okuma engineers were struggling to find a way to control the natural tendency of machine components to expand during machining operations, they had an epiphany, according to Okuma’s Senda Harumitsu. “We were doing thermal analysis day after day when a new idea emerged: Even if we go all out and cool or insulate the machine room or the heat-generating parts as we do the spindle, it won’t work. It would drive up costs too high and no one would use it. What we need is high-accuracy machining merged with thermal-deformation control.” 
For shops that regularly run high volumes of parts, a rotary transfer CNC machine can significantly improve productivity and profitability. Because rotary transfer machines enable manufacturers to completely machine a part in one operation and provide quick and easy changeover within part families, they reduce labor expense and deliver a lower cost-per-part.
