It's time to begin relabeling "Factory of the Future" as "Potential for the Present." As evidence, consider the technological capabilities already emerging in today's machine tools.

One example is the strategic benefits of a "green" machining strategy at Ford Motor Co.'s Van Dyke Transmission Plant in Sterling Heights, Mich. By implementing machine tools incorporating Minimum Quantity Lubrication (MQL), the plant improves part quality and cuts piece-processing cost, says Jim Braun, vice president, product development and standardization, MAG Industrial Automation Systems.

Ford reports that nearly dry MQL machining slices seven figures from initial system cost for unneeded coolant tanks and high pressure supply systems, reduces operating costs, and improves plant air quality. More importantly, the part quality level achieved with MQL is equal to or better than comparable wet machining operations. That was documented last spring when the plant finished first in Ford's 2008 North American Powertrain Environmental Performance Award.

The Van Dyke plant currently uses more than 120 MAG CNC machines equipped with MCL or a hybrid system combining CNC and special machines. MQL is a nearly dry machining process that uses a through-tool oil mist tailored to provide just the right volume for ideal lubrication at the interface of tool and work surface. The amount of lubricity is controlled for the particular machining operation and tool, such as tapping or face milling. MQL reduces metalworking fluid flow from gallons per minute (in traditional wet machining) to milliliters per hour, Ford reports.

What were once "Factory of the Future" goals have become today's competitive differentiators, says Jim Braun (pictured below), vice president, product development and standardization, MAG Industrial Automation.

The plant's most recent green-machine installation in early 2008 included 55 MAG horizontal machining systems configured for 4- and 5-axis work to produce aluminum parts for the 6F midrange FWD transmission. The high-speed machines complement MQL with a proprietary real-time temperature compensation system that constantly monitors the machine, the part and ambient air to ensure consistently precise work.

Ford says the steeply angled interior of the machine, coupled with a chip evacuation system, eliminates the need for chip-flushing coolant and the resulting cost for pumps, filter media and chip drying. The machining envelope is kept under negative air pressure, with chips and oil mist being pulled out in an airstream, then through a centrifuge and filter system.

Dry chips collect in a hopper and clean air is returned to the plant or back of the machine enclosure. A Ford study indicates that the filtered air from the chip evacuation system is as clean as typical office air.

Research by MAG Powertrain North America shows that the investment, operation and maintenance costs of traditional coolant systems can easily reach 15% of the lifecycle cost of a machining system, says Ron Quaile, vice president, proposal, estimating and marketing.

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