THE TRUTH

ABOUT COBALT
POWDERED
METALLURGY HITS
ITS GOALS
ARTIFICIAL INTELLIGENCE
RELEASED FROM
CAPTIVITY

A M AG A ZINE
F RO M S EC O
I S SUE 1. 2 018
 Contents
EDGE ISSUE 1 – 2018

04 NEWS AND PRODUCTS

06 CASE: QUALA-DIE INC.

A POWDER KEG OF PRODUCTIVITY
Helping to drive the powdered metallurgy
sector.

12 TREND: HIGH-PRECISION MANUFACTURING

REJECTING SECOND BEST
First-time-right and near-net-shape
approaches.

14 SUSTAINABILITY: HEALTH
GOOD NEWS ON COBALT
The results of a new major
scientiic study.

17 CUTTING EDGE
PATRICK DE VOS ON R&D
The beneits of Seco’s Global Tool
Deterioration Analysis.

18 EDGE AND YOU

MACHINE SKILLS
Meet an aspiring CNC lathe master.

COVER STORY

21 CASE: GLOBO MACHINING

A SKY-HIGH PARTNERSHIP
Serving Embraer with help from Seco.

25 EDGE-UCATION
FACTORY ROBOTS GET SMARTER
How AI is changing manufacturing for ever.

28 PRODUCTS
JETSTREAM TOOLING
Towards better chip control and uptime.

“
Machining is not an
exact science, but when
you try to approach it
in a scientiic way, you
will most likely achieve
better results.”
Jan Bruurs, p.12

2 EDGE (1. 2018)

 A safer workplace
for everyone
Seco has long recognized that its people are
one of its most important – and precious – assets.
We work tirelessly to ensure that all Seco work-
ers have safe and healthy workplaces, are able to
return home uninjured each day, and can have
the expectation of a long and healthy life. So we
are delighted by the results of a new, large sci-
entific study showing that long-term exposure
to cobalt in metal-industry workplaces does not
increase the incidence of lung cancer. The study
published in The Journal of Occupational Health
and Medicine included health data from over
15,000 Sandvik workers stretching back as far
as the 1920s. Seco can take particular pride in
the finding, given that the research began with
an occupation health study at Fagersta which in
turn sparked interest across Sandvik and then
within the International Tungsten Industry
Association. (See page 14).
Another crucial focus area for our company
is keeping at the forefront of industry develop-
ments and ensuring customers always have
the most appropriate advice and tools. You
can read more about developments around
first-time-right and near-net-shape approaches
being used by high-precision manufacturers in
our trends section on page 12.
Enjoy your reading!

HELENA SÖDERSTRÖM
VP MARKETING & PRODUCT LINES
EDGE@SECOTOOLS.COM

EDGE is a customer magazine from

Seco published in 8 languages

“
Now I understand it’s a
very interesting line of
work and an underrated
profession.”
worldwide. Seco Tools AB Marketing
Department, 737 82 Fagersta, Sweden. Phone +46 223-400 00
Internet www.secotools.com Publisher Helena Söderström E-mail
helena.soderstrom@secotools.com Managing editor Jennifer
Gaufin E-mail jennifer.gaufin@secotools.com Editorial production
and layout Appelberg Publishing Group Project manager Anna
Gullers Editor Daniel Dasey Art director Cecilia Farkas
René Kling Hansen, p. 14 Print Elanders Cover image Getty images

EDGE (1. 2018) 3

 NEWS AND PRODUCTS

NEWS FROM THE TOOL EXPERT

PIERRE ZUNINO joined Seco for

what he thought would be a six-month
posting back in 2006. Twelve years
on, he has held several roles, still
enjoys working with the company and
currently holds two positions: Product
Manager for Boring and Steadyline
Turning; and Product Information and
Communication Leader, where he
heads up a team of four.

PHOTO: SECO TOOLS

QUICK FACTS

Name: Pierre Zunino

Age: 36
Education: Studied IT (reluctantly),
Francisco Otero Alvarez with his former colleagues and his traveling companion – a three-cylinder,
then moved towards marketing (loved
1200 CC Triumph Tiger Explorer.
it). Has an MSc in Marketing Manage-
ment from the UK.
Career: Joined Seco with the aim of
traveling after six months, but never
actually quit Seco. Instead he got a
position as a communication oficer,
then as a marketing project manager
and eventually Product Manager (Bor-
ing Heads) as part of the Holemaking
Farewell tour
product line, before taking his current
position in the Tooling Systems prod-
uct line.
on a motorbike
In the lead-up to his retirement from Seco in Spain, Francisco Otero
Alvarez completed a farewell tour across Europe on his motorbike.
He covered an amazing 10,850 kilometers in four weeks.

Seco’s two-day technical conference in
Bulgaria in October focused on the metal
cutting industry’s challenges to achieve the
highest productivity in the workshop. The
event also connecting partners and people
from the industry for sharing experiences
and practices. Bulgaria is one of Seco’s ris-
ing markets and the event an occation for
professionals to upgrade their knowledge.
What was the idea behind the bike tour? And
what was the most memorable part?
I needed a way to transition between my
time at work and my retirement, and I wanted
an adventure. So, that’s where the idea to say
goodbye to everyone in person came from.
Apart from saying goodbye to everyone, the
high point for me was experiencing nature from
some really good roads. I crossed the Alps from
France to Italy and then into Switzerland – it
was beautiful! If you avoid the motorway, there
is also a very beautiful road between Oslo in
Norway and Fagersta in Sweden.
What are you going to miss from your work
life?
Mainly my friends at Seco and many of my
contacts from customer companies.
Where have you been based during your
career?
I started at Seco France in Bourges in
1974. During my 42 years in the company, I’ve
worked both in France and for Seco Spain.
Over the years, I’ve held different positions:
in the custom products department, as sales-
man in Bilbao area, and in France as a machin-
ing applications engineer doing milling and as
Jabro product manager. Over my last 12 years,
I’ve been in charge of the technical depart-
ment in Spain. The last 12 years have been
the best, as I have been working with custom
products like heavy duty disc milling cutters
for marine crankshafts – the largest ones Seco
makes – chamfering cutters for wind power
generation and so on.

4 EDGE (1. 2018)

 “Today’s manufacturers should not underestimate Tool Deterioration
Best Practices

the value of technology. Rather than maintaining

a shortsighted ixation on cutting costs, we should
consider investing in cutting-edge technology that
can potentially launch operations to new heights.” AN INDISPENSABLE
WORK TOOL
JOE MORGAN, PRESIDENT, This text book deals with one of the
SQUARE DEAL MACHINING INC. most crucial elements of the machining
process – tool deterioration. Due to its
importance in machinability models,
deterioration lies at the heart of most
machining-process problems. It is also
a crucial measure when making inal
evaluations of modiications.
This book focuses on tool deteriora-
tion across all the main metal cutting
applications and would make an indis-
pensable addition to the toolboxes of
all machining experts. Its target audi-
ence is anyone who wants to gain a
better insight into the phenomena that
cause tool deterioration as well as a
PHOTO: GETTY IMAGES

best-practice overview on how to han-

dle and control them.
The Hassan
II Mosque in
Casablanca,
Morocco.

NEW GATEWAY TO NORTH MOROCCO ALGERIA TUNISIA

AFRICAN MARKETS
The Maghreb region of North Africa
takes in the countries of Morocco, Tuni-
sia and Algeria and is often regarded as
one of the continent’s ‘tiger econo-
mies’ thanks to its young, educated A cobot(1) or co-
population and high growth rate. The
region has a privileged relationship with
robot(2) (from
France and is a gateway from Europe
to Africa.
collaborative
In July, Seco established a presence
in these fast-growing countries through
robot) is a
its new subsidiary based in Casa- robot intended
blanca, Morocco. The move relects
the Moroccan and Tunisian markets to physically
becoming a major investment hub for
international aerospace and automotive interact with
subcontractors. Algeria, meanwhile,
has a major gas production industry
humans in
and a focus on power generation and
agriculture.
a shared
Management support for the
Maghreb subsidiary will be provided by
workspace.
Seco Tools France.

EDGE (1. 2018) 5

 QUALA-DIE CASE

A POWDER KEG
OF PRODUCTIVITY
With demand for powder
metallurgy (PM) com-
ponents on the rise, PM
tooling manufacturer
Quala-Die Inc. is always
looking for ways to boost
output. Seco cutting
technology has allowed
the company to hard mill
and hard turn many tools,
increasing productivity.

PHOTOS BY PONTUS HÖÖK

Todd Schatz is a
machinist in Quala-Die’s
connecting rod area.

6 EDGE (1. 2018)

EDGE (1. 2018) 7
 QUALA-DIE CASE

Richard D. Schatz,
General Manager
and Vice President at
Quala-Die.

THERE’S A SIMPLE reason why tool and

die manufacturer Quala-Die Inc. sits in the
heart of Pennsylvania in the United States.
The company serves the powdered metallur-
gy (PM) industry and, as General Manager
Richard Schatz explains, the surrounding
area creates more PM components than any-
where else in the world.
Quala-Die was founded in 1978 in the
basement of the Schatz family’s home and
its specialization then, as it is now, was
serving the PM compaction sector. Busi-
ness flourished and the workshop quickly
evolved. A new facility was built as the
business grew from two to 100 employees,
“We closely
becoming the largest PM compaction tool-
ing supplier in the industry. In October
partner with
2016, Quala-Die, Inc. was acquired by anoth- our suppliers ence robust growth and faces a constant
er well-known Western Pennsylvania compa- challenge to boost capacity and output to
ny, Penn United Technologies, Inc. of Cabot to ensure we keep pace with customer demand. And
and Saxonburg. It has now added to and
complemented Penn United’s already broad
always have according to Schatz, the key to overcoming
these challenges is always having the most
range of manufacturing service offerings. the latest and technologically advanced facility and team
The use of power metallurgy components possible.
is particularly popular in industries such as greatest.” “To accomplish that, we have to maintain
automotive, power tools, appliances, RV/ efficiency and grow in pace with developing
RICHARD SCHATZ
ATV, aerospace, medical and oil & gas. As a technology,” he says. “That means we closely
result, Quala-Die has continued to experi- partner with our suppliers to ensure we
8 EDGE (1. 2018)
Above: Seco Technical always have the latest and greatest, whether
Applications Engineer Kent
Howard and Quala-Die that is a machine tool, employee training,
Production Manager John tooling or even machining strategies – two
‘JP’ Cummings have a
discussion in the quality
of which for us lately have been hard milling
control room. and hard turning.”
Today’s PM compaction processes are
fast, efficient, and extremely accurate,
thanks to advancements in powders, dies,
tooling and presses. These all allow for the
production of components with improved
densities and surface finishes as well as near-
net shapes that are closer to final size than
was thought possible until very recently.
One of Quala-Die’s customers, for
instance, produces PM near-net-shape parts
that are within +/- 0.0004" (0.01 mm); and
because the parts are so close to finished
size they eliminate the need for any second-
ary finishing processes.
To produce the PM tooling that gener-
ates such parts, Quala-Die would typically
either grind or electrical discharge machine
EDGE (1. 2018) 9
 QUALA-DIE CASE

(EDM) them. But with the latest in cutting

tool technology, such as end mills and turn- “We can now
ing inserts from its tooling partner Seco, the
workshop hard mills and hard turns many
produce full
more of its parts.
Running on high-end machine tools with
tool sets  at a
advanced probing systems, tools from Seco price point that
allow the shop to produce parts with toler-
ances as tight as +/- 0.0001" (0.003 mm), and
then makes the
with extremely fine finishes for closer punch-
to-die fits, resulting in much more precise
PM process
PM production parts. afordable.”
Both hard-milling and hard-turning
machining strategies contribute signifi- RICHARD SCHATZ
cantly to Quala-Die’s ability to quickly and
cost-effectively produce its often complex
and high-precision press tooling. Hard
machining reduces the amount of finishing
processes such as EDM and grinding need-
ed for the tooling and thus shortens overall
part turnaround times. Plus, the resulting
PM tooling lasts much longer.

ACCORDING TO SCHATZ, today’s machine tool capa-

bilities allow the shop to take full advan-
tage of Seco’s tooling for hard machining
and thus reduce setups and setup times
that would be quite costly if the part was
processed with EDM or grinding. “We can
now produce full tool sets – thanks to hard
machining – at a price point that then
makes the PM process affordable, so more
shops consider the process for their compo-
nents,” he says.
Quala-Die has worked with Seco for
over 35 years. One of the many significant
contributions Seco has made was when the
tooling company suggested Quala-Die use
hard milling techniques and Seco’s Jabro
line of solid carbide end mills. Following up
on that success, Quala-Die employed Seco’s
Niagara Cutter diamond coated carbide
end mills for milling abrasive graphite EDM
electrodes.
TODAY, QUALA-DIE employs a wide variety of Seco
solid end mills to easily and confidently mill
tool steel components as hard as 60–65 HRC.
These steels have relatively high amounts
of vanadium and chromium, making them
as hard as traditional high-speed steel
(HSS) end mills. That fact makes HSS tools
impractical. As a result, many metal working
10 EDGE (1. 2018)
Quala-Die, Inc
Founded: 1978,
Purchased by Penn United
Technologies, Inc. in 2016
Location: St Marys, Pennsylvania, USA
Employees: 100+
Specialization: Producing tooling for
powdered compaction tooling industry
Total manufacturing space:
4000 square meters
Total years as a Seco customer: 35
companies believe the only way to produce
these hard parts is to use grinding opera-
Tools from Seco tions. But this is no longer the case thanks
to advancements in flute design and helix
 Niagara and Jabro solid-carbide end-
angles, along with substrate and coating
mills, including the diamond line for
structures.
milling its graphite EDM electrodes
For its hard turning, Quala-Die uses
 JS532-NXT and JH112-HXT, Seco
CBN insert grades TH 1500 and
TH1500 and CBN200 Seco insert grades
CBN 200 and CBN 010 for hard- and eliminates having to cylindrical grind
turning part IDs and ODs. The TH1500 grade’s
 Diamond ball nose end mill DS-4 profile includes a textured -based Al2O3
 Niagara MB215M solid carbide end- CVD coating, Ti (C,N) middle layer and
mill for hardmilling a superfine grain substrate that make the
Quala-Die machinist Jason Wurm at work in the hard turning
operation. A selection of tools
in the Quala-Die
workshop.

grade well suited for machining hardened

steel workpieces.
Schatz adds that Quala-Die sees a lot of
growth potential not only in the PM indus-
try but also in diversification. The shop
would like to expand into other industries,
such as the rotary die industry, and do more
prototyping and production jobs, especially
where connecting rods are concerned.
Quala-Die plans to continue to invest in
equipment and human resources, as well as
optimize its machining capabilities. And for
that, Schatz says the shop will rely on Seco.
EDGE (1. 2018) 11
 TREND MACHINING
REJECTING
SECOND BEST
With customers expecting costs to be kept in check, high-precision manufacturers are
striving to get things right the irst time.
BY ELAINE MCCLARENCE PHOTOS BY MALOU VAN BREEVOORT
0
NE OF THE PARADOXES of the
machining process is
that to add value to the
end component you first need
to take material away. This is
particularly true when it comes
to highly complex and critical
parts destined for high-preci-
sion uses – such as in the medical
equipment, semiconductor,
aerospace and defense sectors –
where parts take on significant
12 EDGE (1. 2018)
Jan Bruurs measuring the frequency response function at the tool tip
of a shell mill. This will help determine the optimal feeds, speeds, and
depths of cut for this tool assembly combined with the machine tool
spindle.
value after machining. Increas-
ingly, producers are aiming to
take away as little material as
possible by using the most effi-
cient techniques.
The development of advanced
machining processes has made it
easier to produce parts that were
once difficult to create. There is
also a trend for increased com-
plexity in the form of combining
several parts into one compo-
“
Machining is not an
exact science, but when
you try to approach it
in a scientiic way, you
will most likely achieve
better results.”
Jan Bruurs
nent. This is placing pressure on
manufacturers to optimize their
machining strategies to ensure
accurate dimensions and toler-
ances as well as repeatability in
the manufacturing process.
Jan Bruurs is Technical Spe-
cialist for Tooling at KMWE
Group, a company that special-
izes in high-mix/low-volume
and high-complexity machin-
ing for high-precision indus-
tries. He explains, “This trend
means that greater numbers
of long tools [with protruding
length ≥ 5× Dc] are needed to
machine these parts. To use
these long tools efficiently, the
tool cutter frequency must be
harmonized with the domi-
nant natural frequency of the
system. The system consists of
the combination of the machine
tool spindle, the tool holder,
and the cutting tool. Using
this approach, we can achieve
a first-time-right percentage
for long tools of approximately
90–95 percent.”
Bruurs says it’s important for a
components manufacturer like
KMWE Group to work closely
with tooling makers to both
optimize tooling and to create
tailor-made tooling solutions to
achieve desired outcomes, such
as producing smaller chips.
AS WELL AS the trend towards com-
plexity, there is a push towards
the increased use of lighter
materials, such as titanium and
its alloys, alongside the use of
more familiar materials such as
aluminium, stainless steel and
heat-resistant steel alloys.
Bruurs explains there is also
demand from customers to con-
trol and reduce costs, a factor
that has led to the development
of the first-time-right concept.
KMWE uses dedicated software
like Vericut and CutPro to simu-
late machining processes prior
to setting up on the machining
centers. “When you strive for a
Jan Bruurs says it’s important to work
closely with tooling makers to both optimize
tooling and to create tailor-made tooling
solutions to achieve desired outcomes.

first-time-right approach, the

better solutions aren’t always
at your fingertips,” Bruurs says.
“As part of our permanent quest
for the better solutions, we must
continually expand our knowl-
edge of machining processes.”
Bruurs says another trend
is the rise of machining of
so-called ‘near-net-shaped’
components where the initial
production of the item is very
close to the final shape. “This is
unstoppable and will become
a larger part of our activities in
the future,” he says. “Because
these components are already
close to their final shape, there’s
a limited choice of appropriate
machining strategies. It will be
a challenge to approach these
products in ways that allow them
to be machined efficiently.”
Despite the challenges, Bruurs
is adamant that ‘second best’
is never acceptable. “Good is
the greatest enemy of better,”
he says. “But that doesn’t mean
you have to give up on best. You
can’t change the principles of FAST FACTS
Name: Jan Bruurs
machining, but by learning to
Age: 52
understand them, you can devel-
Title: Technical Specialist for Tooling at KMWE Group
op better solutions. I personally
Family: Wife and two children
have developed an allergy to
Education: Advanced Machining Course at Manufacturing Automation Labora-
trial-and-error approaches. You tories (UBC, Vancouver), HBO Autodesk Mechanical Designer and
should avoid this approach as System Manager (Ithema, Eindhoven), Application Training Fine
far as possible. Machining is not Mechanical Engineering (Mikrocentrum, Eindhoven)
an exact science, but when you Hobbies: Sports including running, swimming and cycling. Making machining
try to approach it in a scientific processes understandable. Personal development.
way, you will most likely achieve
better results.” o More information: www.kmwe.com

EDGE (1. 2018) 13

14 EDGE (1. 2018)
 SUSTAINABILITY HEALTH

Good news from

cobalt study
Long-term exposure to cobalt does not increase
the risk of cancer among workers at Seco and
other companies in the Sandvik Group. That’s
according to a large scientiic study published
in the December issue of the Journal of
Occupational and Environmental Medicine.
BY KARIN STRAND ILLUSTRATION BY KRISTIAN INGERS

A N INTERNATIONAL STUDY covering

more than 32,000 indi-
viduals in five countries
and spanning many decades has
shown that long-term exposure
to cobalt, which is mainly used in
the hard metal industry, does not
increase the risk of lung cancer.
“Smaller studies had previ-
ously shown an increased risk of
cancer,” says Professor Håkan
Westberg from the Department of
Occupational and Environmental
Medicine at Örebro University,
Westberg. “We started out look-
ing at the cohort with the highest
exposure, but we didn’t find any
excess risk in it. From that, we cal-
culated the approximate cobalt
air-concentrations to which you
could be exposed during your
working life without risk of lung
cancer. Current exposure levels at
the Swedish companies involved
in the study are at or below this
level.” However, Westberg adds
that it’s important to continue the
monitoring of exposure levels as

“
We want to chart
the real situation so
that we can respond
accordingly.”
one of the researchers behind
the Swedish part of the new study.
“But these lacked key parameters
such as exposure based on cobalt
concentrations in the air over
well as prevention and prepared-
ness to prevent the occurrence of
other cobalt-related ill-health.
Seco takes a very positive view
of the study. The company’s glob-
Maria Blomqvist time and smoking habits.” al environmental coordinator
Cobalt concentrations in Maria Blomqvist explains, “Seco
the air have been significantly is a company that wants to rely on
reduced over time. Today, all the facts. We want to chart the real
Swedish companies involved in situation so that we can respond
the study have levels generally accordingly.”
well below the relevant limits. The company has worked for
“So, how can we use the results decades to ensure a good working
from this ‘negative’ study?” asks environment for its employees

EDGE (1. 2018) 15

 SUSTAINABILITY HEALTH

and has taken action to reduce

their exposure to substances such
as cobalt.
“Of course, it’s now good to find
out that nobody in our factories
needs to be afraid of dying from
cancer or other diseases because
of their work,” Blomqvist says.
The legal Swedish limit for
cobalt is 0.02 milligrams per
cubic meter (mg/m3). Seco has
an internal limit of 0.01 mg/m3
and its target is to get it down to
0.005 mg/m3.
Digging deep into the past
“In fact, we’re almost there,” Scope of the study THE SWEDISH COMPONENT of the cobalt The results show that both an
Blomqvist says.  Total cohort study involved studying over excess mortality and increased
Westberg considers that Seco 32,354, of 15,000 people who worked at morbidity rate overall from can-
can take a lot of the credit for the which 15,633 Sandvik’s plants in Fagersta, cer, cardiovascular disease and
fact that the large study took place were in Sweden Gimo and Västberga in Stock- chronic obstructive pulmonary
 Employ-
at all. “It all started with us want- holm. Personnel records at disease are strongly associated
ment period
ing to carry out an occupational Fagersta stretched back to the with short-term workers.
1935−2014
health study in Fagersta,” he says. 1920s, while at Gimo and Väst- “Mortality was significantly
 Three com-
“But, interest was gradually awak- berga records went back to the higher for the entire cohort stud-
panies with
ened throughout Sandvik and also a total of 17
1940s. Details of names, personal ied, especially for lung cancer
ultimately in the International manufacturing identity numbers, duration of and for cardiovascular disease
Tungsten Industry Association sites employment and occupation were and respiratory disease,” says
(ITIA).”  Five countries correlated with mortality and the Westberg. “The excess mortal-
cancer register of the Swedish ity was strongly associated with
National Board of Health and short-term workers, that is, those
“It all started Welfare. The results were then employed for less than a year.
compared with the mortality and Where lung cancer was con-
with us wanting morbidity rate among the general cerned, we noted a reducing risk
to carry out an population and the local popula-
tion in Västmanland, Uppland
with increasing exposure since
the employment period was used
occupational and Stockholm. as measure of exposure. The use
Researchers also looked at what of different exposure criteria
health study in is known as the latency period – based on measurement data pro-
the time between exposure and duces the same pattern. In other
Fagersta.” onset of a disease – and eliminat- words, increased risks at low expo-
HÅKAN WESTBERG, PROFESSOR AT ed those who had contracted lung sure levels but not at high ones.”
ÖREBRO UNIVERSITY cancer so rapidly after exposure The results are based on
that the cause must have been comparisons with the general
something other than cobalt. population, and here differences,
They also had access to historical especially in smoking habits, can
measurement data on cobalt air affect the results. The smoking sur-
About cobalt concentrations in the plants. veys carried out did not show any
“When it comes to smoking significant differences between
Cobalt is a magnetic metallic element. It is present in differ-
habits, it was a bit more difficult,” different occupations over time.
ent alloys and makes alloys very hard and strong, resulting in
increased resistance to breaking. Together with tungsten carbide,
says professor Håkan Westberg “We, therefore, also carried out
cobalt is one of the main constituents of hard metal powder. at Örebro University, one of the analyses in which we compared
Cobalt is often mined as a by-product in nickel and copper researchers behind the study. “We lung cancer morbidity in differ-
mines. Only about 10 percent of the world’s production comes sent out smoking behavior ques- ent exposure groups within the
from mines where cobalt is the primary substance. The world’s tionnaires to living members of cohort exposed to cobalt. We were
largest cobalt reserves can be found in the Democratic Republic the cohort and to relatives of those able to establish that increased
of the Congo. who had died since 1991. However, exposure did not seem to result in
the response rate was low.” increased risk,” Westberg says.
16 EDGE (1. 2018)

ASK PATRICK
Do you have questions?
Send them to:
patrick.de.vos@secotools.com
“
A GTDA is concluded by
providing an overview of
strengths, possibilities
for improvement, and
improvement levers.”
Components in a tool deterioration analysis
TECHNO-ECONOMIC
BOTTLENECKS
Solutions:
GTDA – the path
to eiciency
Tool wear analysis can do more than optimize cutting tool selection. It can also
increase the efficiency of the whole machining process.
THESE DAYS, just about every manu-
facturing operation has heard
about Industry 4.0 and under-
stands that it involves aiming
for operational excellence and
applying modern digitalization
techniques in intelligent ways.
The accepted wisdom is that
to achieve optimal operational
excellence businesses need to
meet three goals: eliminating
or reducing waste; minimizing
inflexibility; and minimizing
variability.
HOWEVER, SECO HAS developed a
more complete approach that
adds extra elements to the
equation. We call it the NEXT
STEP production model. This
involves being in full control
of the machining process, fully
understanding the influence
of the workpiece materials, and
reducing the waste of resources.
It also involves employing pro-
duction economy and first-time
yield as effective measuring tools
and, last but not least, support-
ing all of this through a well-
functioning leadership model.
The thinking behind this
approach is that the efficiency
PRODUCTIVITY
High-performance tooling
of any manufacturing plant is
limited by any bottlenecks in
the manufacturing environ-
ment and system. The slowest
process dictates the speed of the
whole manufacturing process.
TOOL WEAR ANALYSIS has tradition-
ally been used for evaluating the
functioning of a cutting tool
by evaluating wear patterns on
used tools. However, Seco real-
ized that there were far broader
benefits to be gained. We call
this wider use of tool wear data,
Global Tool Deterioration
Analysis (GTDA).
What are the main advan-
tages? Tools cost money and by
linking the results of a GTDA
to the analyses of variables like
cost of goods sold (COGS),
we can more exactly quantify
the impact of tooling cost on
the total costs. Tool manipu-
lation costs time and adding
single minute exchange of dies
(SMED) analysis to a GTDA will
help identify the significance
of tool manipulation. Tool use
has a clear impact on the overall
equipment effectiveness (OEE)
of the plant and on system
VERY DIVERSE APPLICATIONS ECONOMIC PREASSURE
Versatile tooling Cost-eficient tooling
CUTTING EDGE R&D
efficiency. (Value stream map-
ping – VSM – techniques will
reveal how the tools contribute
or detract from this.) For exam-
ple, when system efficiency is
low, the optimization of tools
will have only an arbitrary
effect. But when system efficien-
cy is high, it is critical to ensure
that tools function in a very reli-
able way. In all cases, a tool that
is broken or non-functioning
will create a major bottleneck
with the potential to destroy
efficiency.
SECO’S GTDA helps determine the
real and total impact of cutting
tools on the total manufactur-
ing system. The results form the
basis of simulations that help
determine how various actions
would influence the different
technical and economical KPIs
of the manufacturing plant. A
GTDA is concluded by provid-
ing an overview of strengths,
possibilities for improvement,
and improvement levers. And,
of course, a proposal for con-
crete actions to implement.
QUALITY
Precision tooling
EDGE (1. 2018) 17
 Danish student René Kling
Hansen earned a respect-
able 13th place in the CNC
turning division of World-
Skills.

18 EDGE (1. 2018)


René Kling Hansen
AGE: 21
LIVES: Odense, Denmark
EDUCATION: Studies to machinist at
Syddansk Erhvervsskole College in
Odense, Denmark
HOBBY: Restoring an old house outside
Odense
FAMILY: Mum and dad, big sister
EDGE AND YOU MACHINE SKILLS
An aspiring CNC
lathe master
Becoming a world champion in the CNC turning
event at the WorldSkills trades championships
requires skill, dedication – and the ability to
overcome the occasional set back.
Interview by Lars Österlind Photo by Sophie Dreijer
W HETHER YOU’RE aiming to
become the world’s best soccer
player or a chess grand master, you
won’t get anywhere if you don’t practice.
And the same is true in the field of CNC
turning. Just ask Danish machining student
René Kling Hansen. In the lead-up to the
recent WorldSkills trade skills championships
in Abu Dhabi in the United Arab Emirates, the
aspiring CNC champion put in countless hours
trying to perfect his skills. Seco helped out by
providing him with all the tools he needed to
design the parts to be produced in the compe-
tition, as well as with appropriate training in
dynamic turning.
“I have prepared for this competition for sev-
eral months,” Kling Hansen said before World-
Skills got underway in October 2017. “I have
spent a lot of time organizing my Seco tools,
preparing my toolbox, drawing and program-
ming Mastercam, and just playing around with
the tools so that I’m completely aware of what
they can and can’t do.”
Sometimes, though, hard work and commit-
ment aren’t enough to take the glory. At the
end of WorldSkills, Kling Hansen didn’t gain a
place on the winners’ podium, earning instead
a very respectable 13th place out of a field of
22 competitors. Nonetheless, there’s always
the next competition and Kling Hansen came
EDGE (1. 2018) 19
 EDGE AND YOU MACHINE SKILLS
“Now, I understand it’s a very interesting
line of work and an underrated profession.
You can make so many things, there are
almost no limitations.”
away having met new people, learned new
skills and with an experience he will always
remember.
Competition in the CNC turning division
of WorldSkills took place over three days
with competitors given a new task each
morning to be completed within four hours.
First, they received a blueprint and they
were then required to program a computer
with the proper tools to fit the blueprint
specifications. Competitors then set up the
CNC lathe to produce the required part
using the cutting and clamping tools most
appropriate to the material being used.
COMPETITION WORKPIECES could be made from
aluminium, cast aluminium and steel. “I
think it’s important to stay cool, but I’m
aware that I get really nervous right before
a competition,” Kling Hansen admitted
before the event. “One of the most difficult
20 EDGE (1. 2018)
Why WorldSkills matter
WorldSkills International is a non-proit
organization promoting skills excellence
and development in vocational, tech-
nological and service-oriented careers.
The organization represents 45 skills
and 77 countries and regions around
the globe. The aim is to show how
important skills education and training
is for youth, industries and society by
challenging young professionals around
the world to become the best in the skill
of their choice. There are competitions
nationally, on a European level and on a
global scale.
Plumbers, electricians, machinists,
cooks, welders, mechanics, comput-
er technicians and designers are all
examples of skills and professions in
which young people compete during the
WorldSkills competition. WorldSkills
parts to master is to stay focused and keep 2017 was held from 14 to 19 October
the speed up as there is not much time in in Abu Dhabi in the United Arab Emir-
ates, where 56 nations participated in
the competition.”
49 different subjects.
Despite missing out on a medal, Kling
Seco is sponsoring “Skills Denmark”
Hansen is very happy about his rather hasty
for three years.
choice to become a CNC machinist. “In the
tenth grade, I didn’t know what to do and
tried an internship in the machine shop
at steel structure manufacturer Valmont
SM,” he said. “Now, I understand it’s a very
PHOTO: TONY BURNS, GETTY IMAGES
interesting line of work and an underrated
profession. You can make so many things,
there are almost no limitations.”
Kling Hansen alternates studying to be a
machinist at the SDE (Syddansk Erhvervs-
skole) College in Odense, Denmark, with
an apprenticeship at Valmont in Rødekro,
Denmark. “After I receive my diploma, I
would like to study mechanical engineering The Sheikh Zayed Bridge in 2017 World-
Skills host city Abu Dhabi is a great exam-
at university,” he said. ple of a project that required multiple skills.
 GLOBO CASE

A sky-high
partnership
With demand from major customer Embraer steadily
growing, Brazilian company Globo Machining wanted
to increase its output and quality. A partnership
with Seco has allowed it to do just that.

BY FABIO NACIMENTO
PHOTOS BY LUIZ MAXIMIANO

Globo’s customer Embraer

is a huge player in the
aerospace industry. More
than 80 airlines use the
company’s aircrafts and
Embraer has supplied
dozens of countries with
military aircraft.

EDGE (1. 2018) 21

 Globo Machining’s owners Claudio Chavette, Mauro Ferreira
and Gilberto Geraldo de Oliveira are eager to meet increasing
E
demand from customers.
VERY COMPANY faces chal-
lenges as it goes about its
business. But when your
major client has under-
gone massive growth to
become the third largest com-
pany in its sector in the world,
São Paulo
the challenges tend to be even
bigger. This is the stimulating –
GLOBO MACHINING and slightly scary – situation
Founded: 1985 that major Brazilian machining
Two factories in the Brazilian state of São Paulo company Globo Machining has
Jambeiro unit: 7000 square meters – 200 employees faced in recent years.
Botucatu unit: 5000 square meters – 100 employees For the past 30 years, Globo
has manufactured components
22 EDGE (1. 2018)
used in the aircraft parts pro-
duced by the massive Brazilian
aerospace company Embraer.
And every year as Embraer
has grown and made further
advances on the international
market, so too have its require-
ments for Globo’s products.
Eager to meet the increased
demand for both quantity and
quality, Globo decided its best
option was to strengthen its ties
with Seco. Since 2015, the two
companies have worked in a part-
nership to meet the demands of

Joao Marcelo Nunes and Marcio Gomes from Seco Brazil
help Globo Machining achieve the best possible production
outcomes.
Embraer’s aricraft carry about 145 million passengers per
year.
Embraer. “Seco is much more
than a tool supplier,” explains
one of Globo Machining’s
owners, Gilberto Geraldo de
Oliveira. “It’s a great partner and
contributor, helping us through-
out the machining process and
providing us with important
technical support.”
To help Globo Machining
achieve the best possible pro-
duction outcomes, Seco has
supplied a steady stream of
sophisticated tools along with
detailed instructions for their
use. “Whenever we’re going
to work on a part requested by
Embraer, we forward the project
to Seco technical staff,” says de
Oliveira. “They provide us with
not only the tool for machin-
ing, but with its technical data,
instructions for its proper use
and all the cutting parameters
for the alloy.”
Globo has achieved impres-
sive results since the partner-
ship with Seco began, with
team work helping it become a
more competitive player in the
machining market. “We have
had a significant reduction in
costs and production time,” says
de Oliveira. “And the projection
for the future is even better.”
GLOBO’S CUSTOMER Embraer is a for-
midable player on the aerospace
scene. More than 80 airlines
use the company’s aircraft, with
about 145 million passengers
carried per year. Embraer has
also supplied dozens of coun-
GLOBO CASE
tries with military aircraft.
Meeting the needs of such
a massive company is a serious
challenge, but one that Globo
has proved it is more than ready
to meet thanks to the results of
its partnership with Seco. “We
are pleased with the effort that
professionals from Seco show
us, supporting us at each new
project,” says de Oliveira.
João Marcelo, Aerospace
Specialist at Seco, works on
Globo projects and emphasizes
the importance of constant
evolution in machining pro-
cesses. “When we go beyond just
supplying tools to customers
and assist on every step of the
process, we are able to add far
more value.”
SECO HAS BEEN continuously
evolving the supply of tools for
machining since 2009, when it
began working in a segmented
way across its markets.
This experience and know-
“When we go
beyond just
supplying tools
and assist at
every step of the
process, we are
able to add far
more value.”
JOÃO MARCELO
ledge have made a significant
difference for Globo, which
serves a number of other cus-
tomers in addition to Embraer.
These include Eaton Aerospace,
which supplies parts for Airbus,
and TechnipFMC, which oper-
ates in the deep-sea oil and gas
exploration field.
EDGE (1. 2018) 23
 GLOBO CASE
“We always provide the cus-
tomers with the best possible
strategy for using the tools
for each material, whether it
be aluminum, stainless steel,
titanium or something else,”
explains Marcelo. “Each alloy to
be machined and each part has
its own particularities, which
need to be considered during
the process. It’s know-how that
we have gained from many years
of working in the market.”
Jacques Mazo, National Sales
Manager for Seco in Brazil, says
the partnership with Globo
Machining has been successful
right from the very start. “The
work methodology is driven by
24 EDGE (1. 2018)
In addition to Embraer, Globo serves customers including Eaton Aerospace, which supplies
parts for Airbus, and TechnipFMC, which operates in the deep-sea oil and gas exploration
ield.
joint action plans and includes
“
Globo has chal-
lenged us with
focused work
and we have
constant follow-up and this
makes all the difference,” he says.
MAZO SAYS THAT since the two com-
earned their trust panies began working closely
by responding together, both have experienced
quickly and with growth. “Globo has challenged
excellence.” us with focused work and we have
Jacques Mazo earned their trust by responding
quickly and with excellence to
these demands,” he says.
Márcio Martins Gomes, a
technical sales representative
with Seco, has been involved in
the partnership since the begin-
ning in 2015. He has a good
understanding of the complete
machining process at Globo’s
facilities and emphasizes the
evolution in processes that has
occurred over the last two years.
“This is a job where both sides
are evolving together, resulting
in greater competitiveness in
this market,” he says.
Globo Machining’s co-owner,
Gilberto Geraldo de Oliveira
agrees and points to Seco’s
prompt delivery of tools and
commitment to finding the best
results throughout the whole
process. “We just have to thank
Seco for the opportunity to
work together as a team,” he
says. “We have evolved and we
have grown in this market. We
are grateful for that”.
 EDGEUCATION ARTIFICIAL INTELLIGENCE

FACTORY
ROBOTS GET
SMARTER
No longer just the stuff of imagination, artiicial
intelligence (AI) is now having a major impact on
the way we live our lives. In the manufacturing
and production sector, its inluence can be seen
in the form of increasingly smart robots.
BY JAN LINDROTH PHOTOS BY ABB, SCANIA AND GETTY IMAGES

EDGE (1. 2018) 25

 EDGEUCATION ARTIFICIAL INTELLIGENCE
Y OU DON’T HAVE to look far
to find examples of how
artificial intelligence
(AI) is impacting on people’s
daily lives. Evidence of comput-
ers that can simulate intelligent
behavior can be seen in the digi-
tal assistants – like Amazon’s
Alexa and Apple’s Siri – that
have recently been springing up
in homes across the planet. You
can also see it in services like
Google Translate and in call
centers for products like Micro-
soft software where AI-powered
‘chatbots’ greet people and deal
with their problems. The new
generation of autonomous cars
now hitting roads also use AI.
And artificial intelligence is
also quickly taking off in the
industrial production process –
“Robots
equipped with
AI may be
capable of
reprogramming
themselves by
practicing and
learning a task.”
and in general manufacturing
in particular. While robots and
automation in manufacturing
are nothing new, the new gen-
eration of robots stand apart
from their predecessors in that
they are beginning to think for
themselves, make decisions,
and learn without further pro-
gramming.
A typical industrial robot in
26 EDGE (1. 2018)
use today is programmed to
do a single job very precisely
and accurately. However, each
time a production run changes,
such robots need to be repro-
grammed from scratch, a task
that takes time and technical
expertise. By contrast, robots
equipped with AI may be capa-
ble of ‘machine learning’ – the
ability to reprogram themselves
by practicing and learning a
task. To achieve this, they rely
on a deep neural network that
controls, for example, a robotic
arm. Over time, the network
varies the arm’s behavior and
favors actions that lead it closer
to an end goal, like picking up a
particular object. The process
can also be sped up by having
lots of robots work in concert,
then sharing what they have
learned.
THIS TREND IS likely to see industrial
robots move out of the cages
in which they are currently
positioned for safety reasons
and onto the factory floor where
they will perform increasingly
complex tasks and interact and
collaborate with human work-
ers. This opens the way for a
hybrid workforce where people Above: Caged – Scania’s
and machines work together.
According to market intelli-
cab plant in Oskarshamn,
Sweden, is manned by 283
high-tech robots.
gence consultancy IDC, by 2020
some 60 percent of plant floor
workers at the 2,000 largest To enable artificial intelli-
manufacturing companies in gence and machine learning in
the world will work alongside manufacturing environments,
assistance technologies that ena- massive amounts of data must
ble automation, such as robotics, be analyzed from a range of
3D printing, AI, and artificial input sources such as metal
reality or virtual reality. working tools, mining equip-
One example is Swedish-Swiss ment, worker equipment and
company ABB’s YuMi robot, databases. This allows AI to
which has two arms, is equipped create a holistic view of historic,
with AI, sensors and cameras, real-time and projected opera-
and is capable of collaborating tions, and control a vast network
with humans to perform quite of interconnected sensors
delicate tasks. and robotics within a mine or

plant. Such a set-up is variously
referred to as Industry 4.0 or the
intelligent factory.
WHILE IT’S STILL early days for the
trend to AI in the industrial
sector, things are moving ahead
rapidly. For example, earlier this
year ABB and IBM announced
they would cooperate to acceler-
ate the development of the area
by combining ABB’s expertise in
robotics and automation with
IBM’s AI, Watson.
Above: Is this how tomorrow’s coworker will look? ABB’s
YuMi robot is the world’s irst truly collaborative robot and is
helping to make robot cages a thing of the past.
One such use of the collabo-
ration will be having Watson
help to find defects by analyzing
real-time production images.
Up until now such inspections
have been done manually in a
slow and error-prone process.
Putting AI to work promises to
increase the volumes flowing
through production lines while
improving accuracy and con-
sistency through faster inter-
vention from quality-control
experts.
Intelligent
customer service
Intelligent robots are not the only
area where manufacturing com-
panies are looking at deploying AI.
So-called ‘chatbots’ are becoming
commonplace in consumer-facing
sectors as a way to make customer
service more eficient and user-
friendly.
Chatbots are computer programs
that use artiicial intelligence to
conduct naturally lowing conversa-
tions with people. They are used by
companies to provide help and assis-
tance to customers or employees.
Seco is looking at the possibil-
ity of using chatbots in its customer
interfaces to improve and speed
up service for routine inquiries or
tasks.
“We are exploring and evaluat-
ing various options and how they
could best work together with our
other systems while also having the
capacity to learn and evolve,” says
Brent Wilkinson, E-commerce Solu-
tions Owner at Seco.
Chatbots could take charge of
the larger volumes of relatively sim-
ple and routine inquiries, leaving
customer service staff more time to
deal with more complex issues.
EDGE (1. 2018) 27
 Jetstream Tooling
for better control
Frequent production stoppages to
remove chips during threading cost
businesses valuable time and money.
That’s why Seco has been working hard
to increase chip control and improve
uptime through its Jetstream Tooling
system.
The technology involves directing a
high-velocity coolant stream to the fric-
tion zone between the cutting edge and
the workpiece, providing superior lubri-
cation, cooling and chip removal.
The technology provides the ability
to guide chips away from the cut in a
desired direction.
Jetstream Tooling technology is also
now being used on threading tools.
When used with parts made from
Want more?
WWW.SECOTOOLS.COM
Your digital portal to everything Seco.
videos on how our products shape the metal
28 EDGE (1. 2018)
titanium and similar materials, Jetstream
Tooling can extend tool life by breaking
tough threading chips. When threading
steel and stainless steel parts, cutting
speeds 30 to 60 percent higher can be
achieved without compromising thread
surface quality.
When introducing Jetstream Tooling
technology for threading tools you not
only have the possibility to apply coolant
through a hose, but also square shank
hodlers are designed to use the Seco’s
JETI connection. New adaptors mean it
is now available with Seco-Capto turning
center turrets and HSK-T multi-tasking
machine spindles.
While JetStream Tooling has tradi-
tionally been a bolt-on solution, new
YOUTUBE CHANNEL
Check Seco’s channel on Youtube to watch
parts that build your world.
“The technology involves
directing a high-velocity
coolant stream to the
friction zone between
the cutting edge and the
workpiece.”
products are allowing the coolant to be
delivered to the friction zone via internal
delivery channels thanks to Seco JETI
technology. These include Seco-Capto
turning center turrets and HSK-T multi-
tasking machine spindles.
The JETI range was originally limited
to parting-off products such as JETI
blades, blocks and VDI-to-blade adapt-
ers. However, it has now made its way
to Seco square shank holders for thread
turning (Snap-Tap) and Seco-Capto/
HSK-T-to-square shank holders. This
technology will soon extend to Seco
grooving and parting-off holders with
square shanks.
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