BC Instruments takes the prototype phase very seriously, because we know just how important it is to our clients and their peace of mind. It also serves as the linchpin for the final production run, which means perfection is a must. Here’s how we approach the prototyping process, and why it should interest you.

THE PURPOSE

A design is nothing if it doesn’t function well in a real-world application. Many things look great in theory, but only through application do we discover flaws in the design process that require fixing. This is always in our minds at BC Instruments when we first initiate the prototype phase. It’s important for clients who are committing to a project, and need to be sure that timelines are not missed due to errors in the production process.

At the same time, we recognize that no two product runs are ever truly alike, nor are the prototyping methods. Variances occur constantly, which is why we approach each new prototype as if it were the first. For instance, BC Instruments recently worked with mass spectrometry leader SCIEX on the creation of specific machined parts. Both SCIEX and our team understood the vital importance of prototyping when it came to adhering to geometry limitations and standardized processes to create said parts. This guaranteed that BC Instruments was able to serve the needs of SCIEX by determining the correct processes needed for final output. None of this could be achieved without prototypes that allowed BC Instruments and SCIEX to confirm the final designs.   

THE INITIAL PROTOTYPES

Prototyping can involve one, or several different models depending on how well the design translates to a real-world part. Oftentimes a prototype will serve to confirm the accuracy of a design, while others will point out flaws that require correction. During this phase, our prototypes don’t need to look perfect or polished – they simply need to function, and be accurate. The focus is on communicating the validity of a design before we move to the production run.

This approach can save massive amounts of time, as well as money. The former is sometimes more important than the latter, especially when it comes to the clients BC Instruments services in high demand industries such as Electro-Optic, Medical and Nuclear. 

TESTING & RE-TESTING

BC Instruments implements a rigorous testing process to make sure that products move from the prototype phase to production in a seamless transition. This testing involves putting each prototype through its paces to guarantee that it adheres to the exact specifications laid down by the client. Each piece must fit the greater sum of the final project, which is why we eliminate any inconsistencies and issues long before the production run begins.

Clients play an active role in the prototyping phase, as well. Their surveys and opinions are vital as we move into the production phase, and this is especially true during the R&D process. Once the prototype is complete and the client is satisfied, we move into the planning phase to prepare the entire production run. This involves optimizing our workflow and machinery to guarantee on-time (or in many cases, before) delivery, done to precise specifications.

For more information on how BC Instruments can prototype your next design, please contact us today. We’d love to walk you through your process so you can see how we approach this most important of phases.

The post The Prototype Phase, And How We Approach IT appeared first on B.C. Instruments.

So, how does BCI navigate these pitfalls and prevent them from popping up during our production process? First, we need to identify the five most common problems with CNC machines, before we generate fixes for them. Here’s what they are, and how we deal with each one.

#1) CHUCKS AND FIXTURES

There are times when chucks and fixtures on CNC machines cannot adequately hold the machined piece. In this case, vibrations and shifting can occur which can spell big trouble for the production process. Our solutions are rudimentary, and usually involve an elevated approach to the problem. For instance, we first check to make sure the piece has indeed been secured correctly before moving onto other things.

We check to make sure the grips can adequately hold the piece, we check the hydraulic pump and pressure, and we check to make sure other technical issues like foot switch problems or lubricant issues aren’t at play. Since improperly gripped machine parts can lead not just to damage, but operator injury as well, we make absolutely sure our CNC machines clutch their materials correctly, the first time.

#2) OVERHEATING

Due to the extremely high volume orders we take from our clients, our CNC machines are running almost constantly. This means overheating is a factor that we must take into account. Thankfully, we plan ahead on this to make sure all of our machines are working in tip-top shape. It’s important to remember that the basic function of CNC machining means that heat will be a natural result. Our machine tools can hit temperatures as high as 150 degrees, or more. Care must be taken to make sure that this doesn’t affect our machine, or the part in question.

Cleanliness is key, and we make sure our machines are thoroughly wiped down, and that all dirt and debris have been removed. Metal shavings can contribute greatly to overheating, which is why we adhere to a strict cleaning schedule. Overheating can occur from other sources, however. Running a CNC machine at high RPMs for a prolonged period of time means adhering to some standards.

#3) OPERATOR TRAINING

Human error is a constant in any business, but it can be mitigated through proper training and adherence to guidelines. In the case of CNC machining, this means training our operators on how to use the CNC software which runs each machine, plus a thorough understanding of G and M codes, setup and the inputting of data.

We consider this to be of maximum importance, and it shows in the skill of our operators. Machines can only do the job, but the human element is what counts. This is how we continue to please clients the world over, throughout a multitude of important business sectors.

#4) POWER SUPPLY ISSUES

Believe it or not, sometimes the most common problem is also one of the most basic. CNC machines are quite complex, and they can be hobbled by power supply problems. This can often take the form of incompatibilities between the machine and the power socket in question.

We make sure that our CNC machines are running on compatible power supplies with correct voltage settings required for the input side. If we do experience power supply issues beyond that, we bring in certified electricians to make sure there are no faults to our power supplies on the opposite end of the connection. Stable power flow is an absolute must during a CNC machining run, and we do regular checks to make sure ours are running at peak efficiency.

#5) WRONG TOOLS OR SETTINGS

This is a common issue with many precision machining companies, and it really shouldn’t be. In order to successfully complete a production run, one must choose the appropriate cutting tools and settings before the job begins. Failure to do so can result in damage to the finished product in the form of burn marks, rough edges and corners, or visible cutter marks, all of which are unacceptable.

Thankfully, BCI is ahead of the curve on this issue, thanks to over 40 years of experience in the business. Still, it is considered one of the biggest problems faced with CNC machines. The solution lies in the planning stages. Make sure to determine early on the best tool for the job, and do a trial run just to make sure everything is Okay. If not, one may be wearing out their tools faster than anticipated, while ruining their client’s job in the meantime.

For more information on how BCI’s attention to detail and quality excellence has made us a prime player in the Precision Machining industry, please contact us today.

The post 5 COMMON PROBLEMS WITH CNC MACHINES, AND HOW WE FIX THEM appeared first on B.C. Instruments.

Technology has come a long way in our field, but there’s simply no substitute for a skilled CNC machining operator who knows the ins and outs of the job. Like any skilled trade, CNC operators must possess and demonstrate several key skills required to succeed at B.C. Instruments.

Due to the highly precise nature of the parts we manufacture for some of the world’s most demanding industries, second-best is simply not acceptable. Here are the skills our CNC operators apply every day at BC Instruments.

CAD/CAM KNOWLEDGE

CNC machining is a process driven primarily by CAD/CAM technology, which stands for “Computer Aided Design�and “Computer Aided Manufacturing,�respectively. Anyone who has worked with this type of software before knows how precise the designs must be. This is where the process starts, and if the design is wrong, the end product will also be wrong, even if it’s off by a few millimeters.

Our operators know how to navigate this interface to guarantee that designs are double-checked before a run is produced. Their experienced eyes can spot errors and defects in the design before the final product is created, thereby saving time and money. This is absolutely vital when it comes to sticking to strict deadlines.

TRADE SKILLS

It’s important for our operators to understand all the processes of CNC machining, including the hands-on work. This means possessing knowledge of physical skills such as manual grinding and drilling, which are vital for many product runs. They must also be able to check and verify (and if necessary, check again) product dimensions using precision tools. This is mostly done in the prototype phase where any and all defects and kinks are worked out before the final run is produced.

TECHNICAL KNOWLEDGE

Our operators may know the software, and they may be good with their hands, but gray matter is just as important. These skilled workers can read technical blueprints as if they were travel brochures, not to mention technical instructions and models. Without a solid understanding of these fundamentals, it’s impossible to move onto the crafting process without error.

Those proficient in math tend to have a field day with CNC machining. This is especially true when it comes to calculating schematics to ensure correct sizes, shapes and designs of target products. For example, B.C. Instruments serves the Nuclear Energy industry, so one can imagine the level of peak precision required for a product run.

We are proud of our CNC operators who continue to form the backbone of our operations at BC Instruments. With decades of experience, we know what our clients require, and failure is not an option. For more information on our CNC machining services and how they can serve your company during its next production run, contact B.C. Instruments today.

The post CNC MACHINING & THE SKILLS REQUIRED BY OUR STAFF appeared first on B.C. Instruments.

On Monday July 9th, 2012, Mayor Steve Pellegrini along with King Councillors Cleve Mortelliti, Peter Grandilli, Linda Pabst, Bill Cober, Debbie Schaefer and Avia Eek presented the Conzelmann family with a framed acknowledgement in appreciation of the contributions BCI has made to a prosperous and sustainable community in King Township.

The post BCI Presented with Award from King Township appeared first on B.C. Instruments.

At the OCNI (Organization of CANDU Industries) annual general meeting on November 10, 2011 Harshad Patel of B.C. Instruments was presented with the OCNI Presidential Award by Ron Oberth, President of OCNI. The award was for “For the leader within an OCNI member company whose actions most clearly upheld the values of the OCNI and contributed to the ongoing health of the Canadian Nuclear Industries� (OCNI) has about 160 member companies supplying services to CANDU nuclear reactors.

The post OCNI Presidential Award appeared first on B.C. Instruments.

From humble beginnings in our one car garage in 1971 I truly doubt either one of my parents could have ever imagined in their wildest dreams that B.C. Instruments would grow to be a world class precision machine shop that has developed a reputation for quality, customer support and employee development opportunities.

What a challenging but noble decision that was. Did you know that In North America, 70 per cent of new jobs are created by family businesses? In addition approximately 60 per cent of Canada’s Gross Domestic Product is generated by family businesses. The difficult reality is that about 70 per cent of average family businesses never make it to the second generation. Luckily for Bruce and I our parents are anything but average. They did an amazing job of not only ensuring that the companies�growth was manageable and the risk was minimized but in Dad’s never-ending desire to learn what made people tick, he infused a culture, a heart and soul that is truly unique not only in manufacturing but I suspect most companies in the world.

I know I speak on behalf of all employees when I say thank you so much for all you both have done. The transformation from that original spark of an idea in Pottageville of having your own small family business some 40 years ago to this wonderful group of talented individuals has been exciting, scary, challenging, often difficult, rewarding but almost always Happy Days.

Roger Conzelmann, President

The post B.C. Instruments celebrate their 40th Anniversary appeared first on B.C. Instruments.