5 Lessons I learned about our machining business.
Last month I was privileged to attend Horn Technology Days.
Here are some  5 6 lessons learned.
Lesson Number 1- It’s not one thing.

  • There is no magic bullet.
  • There is no miracle pill.
  • Machining is a system.
  • Understand the system, and address system weaknesses.

NoMagicBullet
Stop looking for magic answers. There is seldom a single change that  you can make that will single -handedly optimize your process. You must consider the entire system. I took in every technical session while I was there. I expected to be told that “whatever it is I’m showing you” is the answer to your machining problems.
I was not told that at all. In all of the sessions the focus was on understanding and optimizing and understanding the interactions of the system and its components. Very refreshing.
Lesson Number 2- In our business, success is defined by sustainability, not lowest price.
By sustainability, I do not mean Greenwashing.

Sustainability is not about Greenwashing!
Sustainability is not about Greenwashing!

To be sustainable, a company must learn to solve problems.
Problems  unsolved have the potential to bring your company down.
How to be come more sustainable:

  • Solve problems first.
  • Solve the problem for good.
  • Understand that the lowest cost over the long term is not the lowest price over the short term.
  • Spend less time on maintenance by planning it.
  • Spend more time on production.
  • Spend more time on innovation.

This is why we have root cause analysis. We should only have to solve a problem once. Assure organizational learning takes place. And move forward.
Lesson Number 3- Pay attention to energy
Energy Quadrennial review
This one was a complete surprise. Who knew that 37% of Machine tool energy consumption is related to coolant and lubricant?

  • Through tool coolant typically runs at a rate of about 1 liter per minute (About a quart  here in the US)
  • Traditional flood coolant is typically 18 liters per minute. (That’s about a 5 gallon bucket in imperial units.)
  • And the through tool coolant is applied exactly where it is needed.

I’m not quite convinced that MQL is the answer for production machining, but I saw some demonstrations that continue to make me think.
On another note, typically utilities run from 6-10% of sales dollars in our shops.  we’ve seen estimates that shop lighting can run as much as 37% of the electrical consumption in Warehouses and light manufacturing shops. Even if you cut that in half, it is probably wise to evaluate your current shop lighting. We can talk about compressed air another time. If you hear compressed air in your shop- you are listening to dollars floating away.
Lesson Number 4- Conventional milling = Conventional rubbing

Your daddy's way of milling is no longer preferred today.
Your daddy’s way of milling is no longer preferred today.

All of the programs  on milling at Horn  showed climb milling as the preferred practice. I’m not going to pretend expertise here- just that what I thought I knew is no longer what I think I ought to know in regards to cutter rotation and material feed. Climb milling is the preferred way in modern shops today.
Lesson Number 5- Be optimistic.
HORN is expanding again. Another new building was being built just down the road.
New building on Dusslinger Way
New building on Dusslinger Way

Why be optimistic? How can you be optimistic?

  • It is easy to be optimistic if you are a private company.
  • If you believe in continuous improvement, then you want tomorrow to be better than today.
  • Today is today, but our way is the future. Our way is going forward.
  • Do it today. For tomorrow.

Can’t argue with that. That is why HORN has a full class of apprentices in development.
How about you?
Bonus Lesson Number 6- “The Best People are the Basis of the Future”

Lothar Horn
Lothar Horn

Lothar Horn shared that thought with me in a private conversation. It really fit hand in glove with HORN’s optimistic approach to the future. By training the people and making available opportunities to learn and grow, the company  is preparing their team for an anticipated, but not yet understood future.
There is a continuous demand to upgrade our tools. We can only meet that demand by upgrading the skills of our workforce and the technology they apply.”
When that future arrives, they know that they have done their best to be prepared for that day and its challenges.
That future will arrive. It arrives every day. What have you done to prepare your shop for the future that will soon arrive?
NoMagicBullet
Greenwashing
Energy
Conventional Milling
Expansion

DSCF5929
I visited HORN to learn about their Workforce Development Program.
 For the German version of this post, go here.

Lothar Horn
Lothar Horn

“The best people are the basis of the future.
Our job is to help our people remain the best.”-Lothar Horn
In Germany they have a saying. It is a play on the word Punkt, which means both “point” and “period.” (“Period” as in “End of discussion!”)
“Der Mensch ist Mittelpunkt ( The man is the centerpoint -implies part of the team, respected)
Der Mensch is Mittel.” The man is center. PERIOD (implies just a means to an end, a resource not respected)
Der Mensch ist mittelpunkt
The man is the center of the company and important for  what it does.

This saying conveys that the human should be at the center of the company and its purpose, not just a means to an end.
But I say “It is really all about the People.”
Our People
Der Mensch macht unser Produkt.
Our people make the product.

 
Der Mensh sichert Qualität.
Our people assure the Quality

Der Mensch ist auch unser Kunde.
Our people are also our customers.

We are all customers, that is my POINT! (Punkt)
What did I learn about workforce development from HORN?
Lothar Horn
Lothar Horn

“You are not just a number, you are a name, everyone is important at HORN.”
And that is all that you need to know about workforce development philosophy.

DSCF5929
I visited HORN to learn about their Workforce Development Program.
 For the German version of this post, go here.

Lothar Horn
Lothar Horn

“The best people are the basis of the future.
Our job is to help our people remain the best.”-Lothar Horn
In Germany they have a saying. It is a play on the word Punkt, which means both “point” and “period.” (“Period” as in “End of discussion!”)
“Der Mensch ist Mittelpunkt ( The man is the centerpoint -implies part of the team, respected)
Der Mensch is Mittel.” The man is center. PERIOD (implies just a means to an end, a resource not respected)
Der Mensch ist mittelpunkt
The man is the center of the company and important for  what it does.

This saying conveys that the human should be at the center of the company and its purpose, not just a means to an end.
But I say “It is really all about the People.”
Our People
Der Mensch macht unser Produkt.
Our people make the product.

 
Der Mensh sichert Qualität.
Our people assure the Quality

Der Mensch ist auch unser Kunde.
Our people are also our customers.

We are all customers, that is my POINT! (Punkt)
What did I learn about workforce development from HORN?
Lothar Horn
Lothar Horn

“You are not just a number, you are a name, everyone is important at HORN.”
And that is all that you need to know about workforce development philosophy.

English translation will be my follow up post.
DSCF5929
Ich ging nach Horn, über Weiterbildungsprogramm erfahren.

Lothar Horn
Lothar Horn

“Die Besten Menschen sind die Basis für die Zukunft.

Unsere aufgabe ist es, unsere Mitarbeiter bleiben die beste.“- Lothar Horn
In Deutschland gibt es ein Sprichtwort:
“Der Mensch ist Mittelpunkt
Der Mensch is Mittal.” (Punkt!)

Der Mensch ist mittelpunkt
Der Mensch ist mittelpunkt

Dies bedeutet, dass der Mensch im Mittelpunkt des Unternehmens, nicht nur Mittel zum Zweck.
Aber ich sage: “Es ist wirklich alles über den menschlichen!”

Der Mensch

Der Mensch macht unser Produkt.
Der Mensch macht unser Produkt.

 
Der Mensh sichert Qualität.
Der Mensch sichert Qualität.

 
Der Mensch ist auch unser Kunde.
Der Mensch ist auch unser Kunde.

Wir alle sind der Kunde, das ist der Punkt!
Oder wie ich lernte Horn:
test
“Du bist nicht eine Zahl, ein Name bist du, jeder ist wichtig. “
 
Das ist alles, was Sie wissen müssen über Weiterbildungsprogramm Philosophie.

English translation will be my follow up post.
DSCF5929
Ich ging nach Horn, über Weiterbildungsprogramm erfahren.

Lothar Horn
Lothar Horn

“Die Besten Menschen sind die Basis für die Zukunft.

Unsere aufgabe ist es, unsere Mitarbeiter bleiben die beste.“- Lothar Horn
In Deutschland gibt es ein Sprichtwort:
“Der Mensch ist Mittelpunkt
Der Mensch is Mittal.” (Punkt!)

Der Mensch ist mittelpunkt
Der Mensch ist mittelpunkt

Dies bedeutet, dass der Mensch im Mittelpunkt des Unternehmens, nicht nur Mittel zum Zweck.
Aber ich sage: “Es ist wirklich alles über den menschlichen!”

Der Mensch

Der Mensch macht unser Produkt.
Der Mensch macht unser Produkt.

 
Der Mensh sichert Qualität.
Der Mensch sichert Qualität.

 
Der Mensch ist auch unser Kunde.
Der Mensch ist auch unser Kunde.

Wir alle sind der Kunde, das ist der Punkt!
Oder wie ich lernte Horn:
test
“Du bist nicht eine Zahl, ein Name bist du, jeder ist wichtig. “
 
Das ist alles, was Sie wissen müssen über Weiterbildungsprogramm Philosophie.

Sometimes the wisdom is just undeniable.
I spend quite a bit of my time writing what I hope to be interesting articles for our many readers. Knowledge retention and thought leadership posts for our member companies.
Written pieces that give the readers ‘Tools They Can Use.
If I’m  writing, I’m  probably not spending a lot of time reading…
So when I got a copy of ph Horn’s latest  World of Tools 2/10 magazine, I was captivated by the following comment made by Lothar Horn, Managing Director.

Lothar Horn

“How can our tools best be used so that the customer can obtain the maximum benefit from this investment?”
At PMPA, we’re pretty familiar with the concept of  ‘Tools You Can Use’– in fact we use it as our Tagline.
But we were really interested in the answer that Mr. Horn gave to his own question:
“…we have developed new products, strengthened support and service and expanded our portfolio in the direction of complete machining.”
Let’s see, how can we as an industry face the challenges of the current market situation?
 1) Use the tools we have to develop new products,
 2) Strengthen support and service to our customers,
 3) Expand capabilities toward complete solutions…
Couldn’t have said it better myself!
You can download the Horn World of Tools Magazine at this link ; just click on the pdf download link for the 2/10 issue.
If this was a quiz, would you have gotten 3 out of 3?
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