Arm your machine tool with a portable CMM - Rapid Traverse

FARO Technologies (Lake Mary, Florida) is best known for its FaroArm portable, articulated-arm CMMs that are used to measure large parts, weldments, assemblies and other components that would be difficult or impossible to bring to a conventional CMM. Now the company has introduced a smaller "personal CMM" designed expressly for the machine shop. Called the FARO Gage, the measuring device has an articulating arm with a 24-inch reach that can reach all exposed features and surfaces of a part without having to be repositioned. A magnetic base allows the unit to be mounted right on a machine tool (see photo at right) or a surface plate on a close-by inspection bench. The measuring arm offers 0.0002-inch accuracy, which reflects the increasing need of shops to hold "tenths" tolerances.

Part measurements are recorded on a laptop computer equipped with the company's Cam2 Measure software developed for feature measurement/inspection and CAD-to-part comparisons where every measured part can be compared to engineering design files. The software is user friendly enough that it can be used by machine operators with no computer skills as a step-by-step guide through an inspection routine. It not only tells the user what area of the part (top, bottom, left side, and so forth) to measure next, but it also tells him or her where and how to position the probe for the reading. The software can also be used for advanced measurement and statistical analysis such as SPC and geometric dimensioning and tolerancing (GD&T). The system records all of the user's measurements automatically and creates comprehensive reports The gage allows the part to be inspected right on the machine, which not only saves time but also avoids the problems that come with removing the part from the machine, inspecting a critical feature and trying to put the part back in the fixture exactly the way it was before. It can be used for a variety of measurements that might otherwise require several conventional hand tools, eliminating their costs and maintenance. It also eliminates the variation in measuring results from hand tool to hand tool and from operator to operator. The gage's articulated arm enables it to measure features and relationships between features that would be impossible to measure with conventional hand tools. Plus, automatic recording of the inspection data eliminates "pencil and paper" errors by operators responsible for maintaining SPC charts.

Right-Now Results

Perhaps best of all, the machinist can check the part immediately after it is machined--or pause to check a feature while the part is still in the chuck or fixture--right at the machine and replace a worn insert, change a tool offset or in some other way make an immediate correction to avoid making bad parts. The operator is also spared having to leave the machine, carry the part to the quality department, and wait in line for time on the CMM.

According to the company, in shops where a machine tool stands idle for 1 hour per shift (at $75 per shift, 3 shifts per day) because it must wait on an operator who is busy inspecting the previous part, the FARO Gage will pay for itself in 4 months. It takes up no extra floor space, an important consideration for crowded shops, and it easily can be moved from one machine to another

Software automates tool inventory tracking

Mentioning the state of Nebraska might conjure images of farmland, goldenrods and cornhusks. From a manufacturer's point of view, the state is home to facilities of all sizes, some of which are located in small towns.

Nestled in a farming community of 1,500 people, MetalQuest Unlimited (Hebron, Nebraska) is a 40-person shop serving the petroleum, energy distribution, hydraulics, agriculture, electronics and automotive parts sectors. At its inception in 1996, the company had one multi-axis CNC lathe. It has since added a variety of multi-functional CNC machining centers and lathes.

Desiring a better method of managing its tooling inventory, the company turned to ToolBoss from Kennametal Inc. (Latrobe, Pennsylvania). Scott Harms, president and founder of MetalQuest, became acquainted with ToolBoss, an e-storage tool inventory control system with imbedded tool management software, when attending the International Manufacturing Technology Show (IMTS) in September 2000. By July 2002, MetalQuest had purchased a one-bay unit. Six months later, a second bay was added, and in early 2004, the company purchased two additional bays. Today, using its four-bay unit, the company stores more than 2,500 tools and controls keys to other cabinets that contain hundreds of other items. Capabilities such as tracking tool inventory, raising operator accountability and providing data about tool usage have provided the company with a means to save time and money. As another result of using the new system, the company reports that machine operators now have an orderly place to store inserts, tools, tool parts and unrelated tools that are commonly used in the shop.

Another benefit is the ability to store multiple items, including non-Kennametal tools, in one drawer, and in a more organized fashion than before. The company has noticeably improved its real-time knowledge of inventory levels. As a result of this upgrade, machine operators can locate tools in 30 seconds, compared to 5 minutes of searching through drawers, toolboxes and canisters on the shop floor. Likewise, it is virtually impossible to run out of tools because restocking of inserts, drills, taps and end mills occurs on an as-needed basis.

Customers also have the option to use job status or "setup" sheets, as well as the optional bar code reader to accelerate setup and production times. This can reduce probable operator errors, such as choosing an incorrect tool for a particular job.

MetalQuest has integrated ToolBoss with its setup sheets, which instruct operators as to how to prepare machines for specific jobs. The appropriate inserts, toolholders, and toolholder parts needed are conveyed to operators. To obtain the necessary tools, users can search or scroll down the computer screen.

"The program was well received on the shop floor," says Mr. Harms. "Within a couple of days, our personnel had familiarized themselves with how the system works and had integrated it into their routine."

During the past several years, the company has transformed itself from a shop producing maximum orders of 500 pieces to one that now produces 500-piece minimum orders. Additionally, its operator-to-CNC lathe ratio to has been reduced to 0.5:1.

The company speculates that if its operations resembled a traditional custom-machined parts manufacturer, it would need to employ ten additional machinists.

The Pentium class computer is loaded with Microsoft Windows 2000 to run Kennametal's Automated Tool Management Solutions (ATMS) software. The menu includes a real-time ordering option that complements the system's tool kitting, presetting and tool assembly management features.

MetalQuest says the network card allows it to maintain the database on its existing network for checking stock, doing analyses and placing orders from other computers.

Although the company has a four-bay setup, each system can control as many as ten bays in one unit, all of which are programmed to store an infinite number of items.

Tool presetting ensures tool quality while saving time

The Edon, Ohio, plant of Metaldyne (Plymouth, Michigan) produces one of the most complex parts on an automobile: the steering knuckle. Irregularly shaped with a variety of surfaces and holes to mill, drill and bore, steering knuckles provide a machining challenge that usually requires some finesse to meet.

Automobiles have either two or four knuckles, which are typically made of steel, cast iron or aluminum, as part of the suspension. Production volume, as well as product quality, is an important consideration when machining these components. To achieve adequate production levels for several knuckles, the plant employs dual-spindle machining centers. Each spindle performs similar operations on left- and right-hand knuckles located in a fixture. Toolholders are shrink-fit HSK 100 and HSK 80.

"We felt that shrink-fit holders were essential," says Chris Filoso, Metaldyne manufacturing engineer. "When compared to collet chucks, hydraulic chucks or other types, shrink-fit holders offer the best possible concentricity and gripping power while eliminating the expense of parts such as collets."Because each spindle performs mirror image operations, our operators must match the tooling used in the twin-spindle machining centers to within 20 microns," he adds.

Previously, the company believed that a shrink-fit tool changing machine and a separate presetter would accomplish adequate tool changing and setting. However, this two-stage process proved to be time-consuming because one machine was needed for shrinking/unshrinking the tool, while a second device was required to measure and preset the tool. Other cons of this arrangement were that the tool setting accuracies mandated by plant standards could not be achieved, and the tool presetter could not automatically write tool data to the Balluff chip embedded in the company's holders.

Anticipating that adequate accuracy and time savings would be realized, the plant acquired a redomatic heat-shrink tool presetter and measuring machine from Zoller Inc. (Ann Arbor, Michigan). Including features such as a Z-axis measuring range of 23.58 inches (600 mm) and a diameter of 15.72 inches (400 mm), the three-axis CNC vertical tool setter and measuring machine is now employed by the company to preset, heat shrink, cool and measure tools in one automated process.

Heat shrinking to a nominal length is only possible when one unit performs the entire process. The system has a 10 kW capacity for shrink fitting shank diameters ranging from 0.12 inches to 1.26 inches (3 mm to 32 mm), and in lengths as large as 600 mm, with heating times varying from 5 to 10 seconds. Cooling requires approximately 30 seconds or less with reliable water-cooled cooling adapters, according to plant engineers.

The machine used at Metaldyne incorporates a vision system that provides automated measuring and inspection of each tool in the plant's arsenal. Two CNC-driven linear slides--vertical and horizontal--position the optic carrier, and the spindle rotation permits focusing on the tool.

"The image processing technology permits automated measurement of tool length, diameter, corner radius and two cutting edge angles," explains Mr. Filoso. "The software detects cutting edges almost instantly, and then the camera in the optic carrier transmits the image of the tool edge to the control and screen."

Mr. Filoso comments that, in addition to ease of use, the system offers various benefits. "The machine can set any shrink-fit tool to the required length within [+ or -] 10 microns," he reports.

"To shrink clamp a tool to a nominal length, our operator need only input data, such as the nominal length, toolholder diameter and tool material (HSS or carbide), via an easy-to-comprehend human-machine interface," explains Mr. Filoso. "Each tool contains an ID number to enable users to retrieve and use this data later on."

The induction-heating coil is positioned over the holder, where the coil then heats the holder. The tool is loaded into the holder, and the CNC-driven tool length stop is said to ensure correct tool positioning--for example, tool tip to gage line. The operator selects one of five cooling adapters and positions it over the holder. After this step, the tool is checked again automatically, and measurement results are transferred to the tool identification chip.

"The entire procedure is carried out in about 2 minutes," says Mr. Filoso, "which includes changing the tools and achieving the accuracies we need." Any correction values are stored and can be used in the next shrink-clamping process

Grinding Machine targets automobile industry

ertical Generating Grinding Machine, Model S 250 G features cast iron machine bed and light metal subassembly, consisting of spindle with electric drive, absolute position encoder, and tailstock. Spindle offers output of 48 kW and max speed of 20,000 rpm. Siemens CNC control system and magnetic encoder ensure synchronization between tool and workpiece. Modular gantry loader allows grinding machine to be directly incorporated in existing production lines.

At EMO 2005, the trade fair for machine tools, production systems and technologies taking place in Hanover this year, Samputensili is presenting this new compact high-capacity machine - guaranteeing gear manufacturers top levels of productivity (above all in the automobile sector).

Bologna, 26th September 2005 - Samputensili, one of the leading companies in the gear-cutting machine and tool industry, is presenting the new S 250 G generating grinding machine at EMO 2005 in Hanover, the trade fair for the entire mecha

Machine Tool Controller Software—CamSoft Corp - Brief Article

The company will be demonstrating Version 12 of its PC-based CNC machine tool controller software, CNC Professional, which now has the ability to do eight axes of simultaneous coordinated motion. The company also will be debuting its latest PC-based CNC machine tool controller software package titled CNC Plus, CNC Plus includes configurable operator screen, limited configurable G and M codes, diagnostic software, servo tuning software, visual logic process editor, automatic machine maintenance reminders, remote machine monitoring, ActiveX and DLL source code, (G40, G41, G42) tool comp, (G94, G95) ipm and ipr for lathes, (G74) lathe peck drilling, (G96, G97) constant surface feed for lathes, (M98, M88) dubroutine calls, threading and tapping, backlash axes compensation, leadscrew axes mapping compensation and advanced mid-program start, allowing the program to begin anywhere.

Information Model for Machine-Tool-Performance Tests - Statistical Data Included

This report specifics an information model of machine-tool-performance tests in the EXPRESS [1] language. The information model provides a mechanism for describing the properties and results of machine-tool-performance tests. The objective of the information model is a standardized, computer-interpretable representation that allows for efficient archiving and exchange of performance test data throughout the life cycle of the machine. The report also demonstrates the implementation of the information model using three different implementation methods

This report specifies an information model of machine-tool-performance tests in the EXPRESS modeling language [1]. It is based on the information model described in the Data Specification for Machine Tool Performance Tests, Version 2.3e [2]. The objective of the information model is a standardized, computer-interpretable representation that allows for efficient archiving and exchange of performance test data throughout the life cycle of a machine tool. It serves as a basis for generating database schemas, database calls, and neutral file formats. Performance test data of machine tools is used for machine acceptance, performance tracking, software compensation, and to evaluate the capability of a machine to manufacture a part to specified tolerances.

The information model specifies the test procedure, the test conditions, the equipment, the measurement set-up, and the test results. The model can be used to describe the properties and results of a performance test at a level close to the raw measurement data. The information elements also enable the user to re-create the set-up, equipment settings, and measurement procedure. The model captures key information on the large variety of possible test set-ups and measurement procedures, which is essential for the interpretation of the test results. A subset of the specification can be used to summarize the test, focusing on performance parameters that are estimated from the measurement results.

The information model addresses machine tool properties that are verified by performance tests. It complements machine-tool-specification data that is not tested, e.g., the machine configuration, the workspace, weight and size of the machine, tool holder standard, auxiliary devices, etc. [3].

The information model is intended to serve as the starting point for a future, standardized representation. The model is expected to change and grow based on further review and future implementation experience.

This report is structured as follows: In the remainder of Sec. 1 the problem statement and scope of the information model are defined; modeling language and implementation methods are identified. In Sec. 2 the information model is presented. In Sec. 3 three sample data files are provided. In Sec. 4 software tools that support the implementation of EXPRESS information models are briefed. Section 5 presents the conclusion of this report. An appendix is provided for describing a set of EXPRESS keywords in Sec. 6. The final section lists the references used in this report.

1.2 Problem Statement

Today's manufacturing industry greatly relies on computer technology to support activities throughout a product's life cycle. Efficient and distributed access to the performance data of machine tools is important in manufacturing. The results of performance tests are used for machine acceptance, predictive maintenance, error compensation, and to evaluate the capability of a machine to manufacture parts to specified tolerances. A critical enabler to the efficient interchange and storage of performance data is a unified information model for the results and properties of performance tests.

Next Best - National Tooling and Machining Association provides referral service for machine tool purchasing - Brief Article - Column

In my February 2001 column, I lamented the fact that our industry doesn't have the equivalent of a Consumers' Guide for machine tools. Responses included several suggestions about other approaches to getting the inside scoop on what machine to buy.

Matt Coffey, president of the National Tooling & Machining Association (NTMA), reminded me of a referral service among NTMA's membership of 2,550 companies. Each year, NTMA members are asked to report any new equipment or software that they have purchased in the prior year. Members willing to talk about their experiences with equipment or software are listed on the members-only section of NTMA's Web site (www.ntma.org) where other members can find them and get in touch. Sounds like a great way to get some honest opinions and one of the many good reasons for joining the NTMA.

According to Tom Charkiewicz, president of MTI Systems, Inc., many of his customers are using the company's Costimator estimating and quoting system to compare manufacturing operations on different models of machining centers, lathes and turret punch presses. The program recalculates from machine to machine such factors as machining time, labor and machine handling elements. Comparison can be made of setup time, time per tool to set up, chip time, tool change time, mm. and max. rpm, horsepower and various cost factors. For more information, TecRight Machine Tool Sales, a distributorship and consulting firm in Rockford, Illinois, has developed a nifty computer program that automatically ranks machine tools by numerical score based on a user-created database of specific design criteria and pricing terms. Called TecScore, the program makes sure the buyer pays adequate attention to technical specifications and capabilities rather than emotional issues and sales hype. The person to talk to about this program is Marjorie F. Palm, president of TecRight, (815) 332-2317.

I'm sure I'll hear more suggestions on good ways to get machine tool comparisons in lieu of a definitive buyer's guide. All of these suggestions are welcome, and all reinforce my original point. Your best bet is to begin with a thorough understanding of your own needs, wants and goals. Nobody can offer you a substitute for this basis to any buying decision.

Bringing The Internet To The Machine Tool

The Internet integrates the factory floor with customers and suppliers, allowing true Enterprise Production Management. The concept of "virtual product" replaces the conventional practice of warehousing inventory.

To be competitive today, manufacturers must manage not only their own internal operations well, but they must also understand and manage all aspects of their external environment that affect production. Real-time two-way communication with the factory floor via the Internet gives managers up-to-the-minute information when they need it, wherever they happen to be. In industry, the Internet promises to connect the enterprise with suppliers and vendors enabling a new paradigm in manufacturing-Enterprise Production Management (EPM).

The use of the Internet will soon force companies to manage production across the extended enterprise. Ordering online is allowing customers to purchase a product tailored to their needs. This custom ordering is shifting manufacturing away from one order of 1,000 units to a 1,000 orders of different variations of a product. Maintaining inventory in a warehouse is no longer possible because the product must be made-to-order. However, the product must be delivered to the customer in an acceptable timeframe so that it feels like the product came from a warehouse. This concept of manufacturing the product after the order is received is called the "virtual product" because the product does not actually exist until after the customer places the order.

In order to create virtual products, it is essential that a company practice EPM. To do so requires a company to have all of its systems connected down to the level of the machine tool inside its divisions and to its extended enterprise, its suppliers. When an order is received, the ERP system communicates electronically with all machines in the supply chain. This new communication of manufacturing information takes supply chain management (SCM) to a new level, a level beyond just electronic purchasing and invoicing. A customer order results in an immediate capacity assessment of what machine time is available in the supply chain. Machining instructions are automatically downloaded to the appropriate machines so that they can begin part production even as the order processing is taking place. Electronically linking the ordering process to the manufacturing process is the link that will enable companies to stock virtual products instead of maintaining inventory. The connection between business-to-business sys tems and the factory floor may be referred to as factory to business or F2B.

Most of the investment in e-commerce over the past 5 years has been focused on improving the connection between company divisions for the purpose of Enterprise Resource Planning (ERP). Other e-commerce investments include connecting vendor and supplier accounting systems electronically and connecting electronically to customers to improve customer service. Today's ERP systems now manage a company's machines and materials in a static manner and proceed to schedule with specific times and dates, often relying upon the efforts (often heroic) of human managers to keep things running. These initiatives ignore connecting to the devices that make up the bulk of the company's capital investment, the machines on the factory floor. These machines contain a wealth of information about what is happening right now, yet this information is not accessible and as a result cannot be used to make critical decisions.

THE CNC AS BARRIER OR ENABLER

To achieve EPM, all machines in the factory must be connected and able to broadcast their status. In the realm of discrete manufacturing, most metalworking shops employ machine tools with computerized numerical control (CNC) systems. Although more than 2 million CNCs are now in production, most have only basic serial communications at low data transfer (baud) rates. The serial connection itself uses proprietary protocols for communication. No communications standard has ever been developed because the CNC has up until now been viewed as a downstream device that processes G-code and controls motion on a machine tool or robot. Most of the machines in production today were created before the Internet explosion took place.

There are several barriers for the introduction of the Internet to the factory floor. No one in an office environment would imagine using a computer that is 8 or 9 years old. In 1993, the so-called 486 central processing unit provided the fastest personal computer on the market. The Pentium-based P60 and P90 processors were introduced in 1994. Office computers are routinely replaced every 3 years, an action justified by the increased productivity available to of the user.

Choate Machine & Tool - Catalog Showcase

Our four Color 2004 catalog is packed full of the best synthetic stocks and accessories available today for all of your shooting needs, Featured in this issue is our new target/varmint stock along with all of our other bolt action, semi-auto and shotgun stocks Our products carry a lifetime warranty. $2.00.

St. Louis NTMA Chapter Meets at Mittler Brothers Machine & Tool

The Greater St. Louis Chapter of the National Tooling & Machining Association (NTMA) held its September meeting at Mittler Brothers Machine & Tool in Foristell, Missouri on September 9th.

Over 70 attended the event. Tours of the multibuilding facility were conducted. The tours included an opportunity to-visit the company's NASCAR Craftsman Truck shop and to see an actual 700HP engine run on a Dyno.

The dinner's main course was prepared on a custom BBQ cooker produced at Mittler Brothers.

During the meeting, new members were introduced, long-time members were recognized and announcements were made about upcoming conferences regarding manufacturing.

Mittler Brother's Mike Mittler gave a brief presentation about the company's history and its current status.

Machine tool sales rise

Orders for machine tools rose 3% in June compared to year-ago sales, representing the first monthly gain in machine tool sales versus the prior year period since November 2000, according to the latest figures available from the American Machine Tool Distributors' Association (AMTDA, Rockville, MD) and the Association For Manufacturing Technology (AMT, McLean, VA).

US machine tool sales reached nearly $245 million, up 3.3% over $236.8 million reported in June 2002, and an increase of 67.1% over May sales of $146.36 million, according to the June US Machine Tool Consumption (USMTC) report. However, industry year-to-date sales of $952.6 million still trailed last year's YTD total of $1.16 billion by 17.9%. The figures in the USMTC report are based on actual data reported by companies participating in the USMTC program

Machine Tool Components And Accessories - Smith-Renaud - Brief Article

HOLD-ROL bearings (right) are used on a Center-less grinder rebuilt with an upgraded regulating wheel and drive unit mounted en it.

Improving Centerless Grinders

One way to improve machine tool performance is to replace older equipment with newer equipment. However, a less costly alternative is to upgrade or remanufacture existing machines. This approach often allows companies to obtain features that would be prohibitively expensive on new machines.

Smith-Renaud (Cheshire, Connecticut) rebuilds Cincinnati Milacron (now Cincinnati Machine) centerless grinders, as well as machines from other manufacturers. These machines are commonly used to finish grind round parts (such as bearings), fasteners, taps and other tough-to-grind parts where machine stability improves the process.

"We have been rebuilding centerless grinders for 20 years," says Tim Emerson of Smith-Renaud. The company has learned that a key to upgrading centerless grinder performance is replacing the regulating wheel spindle bearings. The company used to replace the bearings with duplicate OEM bearings. But then Smith-Renaud started looking at other solutions. What it found were HOLO-ROL cylindrical roller bearings from Kaydon Corporation (Muskegon, Michigan). "We first learned about the bearings at a technology exchange seminar and decided to give them a try," Mr. Emerson says. Due to their performance characteristics, HOLO-ROL bearings offer advantages over conventional bearings in this application. The OEM bearings would require periodic adjustments by an experienced technician, but the HOLO-ROL bearings do not.

HOLO-ROL bearings use hollow cylindrical rollers instead of solid rollers. These rollers are radially preloaded, giving them more radial stiffness than conventional ball bearings. Two performance characteristics create this greater stiffness. All of the hollow rollers are in tight contact with the bearing races, and the rollers all work together to distribute the load. Preloading ensures that roller contact deflection against the bearing races is taken up before a load is applied to the bearing.

Bearing lubricant can flow through the centers of the hollow rollers, dissipating heat more effectively than solid rollers. The bearings therefore run cooler, improving precision, permitting higher operating speeds and extending lubricant life. The hollow rollers also weigh less than solid rollers, so they reduce centrifugal forces at high operating speeds. As a result, contact stresses are lower, and operation is smoother.

These bearings have half the radial runout of an ABEC 9 precision class bearing, so they reduce the radial runout of a regulating wheel spindle. This improved performance is due to three factors:

* Preloading eliminates all internal clearance in the bearing;

* The hollow cylindrical rollers absorb variations in the bearing raceway surfaces and maintain a constant rotating center; and

* The hollow rollers are compressed to the same radial height, and they rotate as if they were all exactly the same diameter.

These bearings can be used for regulating wheel and grinding wheel spindles, but the most significant performance improvements are achieved by upgrading the regulating wheel spindle bearings. The improvements achieved by using HOLO-ROL bearings on regulating wheel spindles are such that Smith-Renaud offers upgrade kits for those wishing to install the converted assembly.

HOLO-ROL bearings improve centerless grinder productivity in numerous ways. First, their lower radial runout permits greater stock removal rates, which reduces cycle time. Second, fewer wheel dressings are needed due to the greater stiffness and decreased vibration of the bearings. Plus, the reduction in frequency of dress means longer wheel and diamond life. Finally, these bearings are lubed for life and sealed when they are assembled. No grease fittings are used, and no adjusting is needed.

Decreased radial runout with these bearings equates to less movement of the regulating wheel shaft and spindle. This reduced movement results in improved part geometry and roundness. Additionally, the surface finish on the part surpasses that of a grinder using conventional bearings.

"HOLO-ROL bearings are more expensive than the OEM replacement bearings that we were using, but the performance benefits are worth the extra cost," Mr. Emerson says. "The bearings reduce maintenance and improve the grinder's performance. From a performance perspective, not only do you reduce scrap with these bearings, but you can also grind more aggressively, so you can make parts faster.

Tool time: how one entrepreneur built a better screwdriver—and used smart networking to get it into Sears stores nationwide

THE ENTREPRENEUR: Allen Kenner, 43, of Ashland, Oregon

PRODUCT DESCRIPTION: The Grip-N-Drive is an upgrade from the typical ratcheting screwdriver. Kenner patented the product's rubber grip mechanism: It spins freely in either direction, but then deforms to grip down on the screwdriver's handle when squeezed. A package of five Grip-N-Drive screwdrivers (two Phillips and three slotted screwdrivers) sells for $19.99 at Sears stores nationwide under the Craftsman label.

STARTUP: Approximately $15,000 for a patent and a working prototype

SALES: Pratt-Read, the Bridgeport, Connecticut, company that licenses the product, expects Grip-N-Drive sales to reach between $1 million and $5 million this year. Kenner gets a percentage as royalties.

THE CHALLENGE: Getting your innovation on the shelves of a major retailer that prefers not to buy from one-line, underfinanced inventors

1. PUSH YOURSELF TO DEVELOP THE ULTIMATE DESIGN. "The handle grips on my early prototypes could spin, but not smoothly," says Kenner, who started developing the product in 1998. "Some people who tried them had a ho-hum reaction to the product. I realized that the Grip-N-Drive needed a grip people could get excited about--one that could spin faster and [more] easily in either direction with a single twist. Once I produced the easy-twist screwdriver, everybody who tried it wanted one."

A big "wow" factor helps, but simplicity also counts because it appeals to people. "I believe in the SMAC tenet--'simple machines are cool,'" says Kenner. "People fall in love with inventions that are simple to use, simple to understand and that work really well. The Grip-N-Drive exemplifies SMAC, consisting of only two nylon snap-rings and a special rubber grip mounted on the screwdriver. Due to the extreme simplicity of the Grip-N-Drive, I had concerns that my idea would be stolen if I manufactured overseas. Fortunately, the simplicity of the design, in combination with the automated product process used to manufacture screwdrivers, allowed me to have the Grip-N-Drive produced in the U.S."

2. MAKE SURE CONSUMERS LIKE THE PRODUCT. "I got feedback on the design and conducted market research by showing my product to friends at parties and other places in town, always getting signed nondisclosure agreements," Kenner says. "I asked successful businessmen for advice and, through networking, found local people who had worked in the hand-tool industry. They provided valuable information and reinforced my belief in the viability of the Grip-N-Drive. Once I felt comfortable with the manufacturing-to-retail price ratio, I began looking at options for producing and marketing my screwdriver."

3. DEVELOP A STRATEGY. Kenner wanted to license his product to a company that could sell it to Sears. "I decided I would have the greatest chance of success approaching a small to midsize company. I also wanted to keep travel expenses down and work with a company I could trust. A local manufacturer, Professional Tool Manufacturing LLC in Ashland, Oregon, which sells its Drill Doctor, a drill-sharpening machine, through Sears, met my criteria."

4. MAKE NETWORKING A PRIORITY. Having trouble getting your foot in the door of a potential licensor? If possible, have someone who already knows people there recommend your product. "Rather than going directly to the company, [in 2002] I asked a friend with a connection [to Professional Tool] to arrange an introductory meeting by explaining to one of the owners that he knew someone with an exciting invention."

5. DON'T SIGN A DEAL TOO SOON. Kenner signed a nondisclosure agreement with Professional Tool, but no other agreement. When Sears requested that some changes be made to the product's design that would raise upfront tooling costs and production costs, Professional Tool graciously backed out of the deal and let Pratt-Read, a leading private-label supplier, take over. By October 2004, the Grip-N-Drive was being sold in some Sears stores, and a nationwide rollout soon followed

Machine tool consumption slumps - Materials Outlook - Brief Article - Statistical Data Included

CHICAGO -- U.S. machine tool consumption totaled $156.17 million in November, down 16.6 percent from a revised $187.27 million the previous month and 46.6 percent below the $292.5 million in November last year, according to a joint report by the American Machine Tool Distributors' Association, Rockville, Md., and the Association for Manufacturing Technology, McLean, Va. "Congressional dithering over economic revitalization has added uncertainty to an already weak capital investment environment," said Don F. Carison, AMT president. "Congress must focus on a revitalization package that will create jobs and encourage productivity-enhancing investments. Congress needs to take action on a meaningful economic stimulus package when it gets back to work next week." Machine tool consumption in the first 11 months of last year totaled nearly $2.5 billion, down 32.9 percent from more than $3.72 billion in the same year-earlier period.

Report Card Time - report on machine tool companies available - Brief Article

The 35th annual report on the performance of major machine tool companies, The Machine Tool Scorecard, is now available. It provides data by rank, company, country, machine tool sales, total sales, net profit, number of employees and sales per employee. Rankings are based on worldwide sales of machine tools; numerical controls sold by machine tool builders are also included. It covers 238 companies from 11 countries, which appear to have machine tool sales totalling $31.3 billion. Increases in sales were reported by 86 companies. The bulletin is distributed by AMT-The Association For Manufacturing Technology