Connect the Silos

Dale  Mahalko, Gilman, Wi USA

Dale Mahalko, Gilman, Wi USA

Anyone who has attempted to implement lean saving discovers that most companies operate inside little silos. The marketing department does not think that they need to link their actions to sales generated or prospects discovered. The engineering / product planning group believes that someone else should define the detail specs for the new product to be developed. The accounting group wants perfect projection of all future expenditures. The sales group wishes that the custom offerings desired by each customer can be delivered in the same time and same price as the standardized offering. We have all been around this merry-go round.

I started to wonder how we evolved to work in silos. I suspect that our upbringing is a factor. Our parents created a sheltered cocoon so that we could grow to the point that we could face all the challenges ourselves. Many of us first experienced swimming in the safety of a wading pool in our back yards.

Becoming a mermaid may be more exciting than we thought pictures by ODDHARMONIC &AJCANN

Becoming a mermaid may be more exciting than we thought
pictures by ODDHARMONIC &AJCANN


A few of the high filers grew to revel in surfing the earthquake waves of the oceans. The work environment throws major challenges at us. I believe that silos have been created as a partial replacement for the cocoons that sheltered us in childhood.

There are high fliers in the business arena as well. In the successful start-up companies they are able to navigate in company size silos. Companies like GE have discovered that grouping high fliers into their own start-up silo is a effective formula to kick-start innovation. I am not sure whether the silo created for this purpose was an invention of the rest of the GE players. The jury is still out on whether it is possible to attract and retain a group of players who are comfortable in working in a company size silo. We will all be watching the Zappos experiment in holocracy

Rough Road Ahead

"Dirt Road -Fremont-CA"by Benefactor 123

“Dirt Road -Fremont-CA”by Benefactor 123

We all cringe when we see a rough road sign in our path. The jagged accelerations chatter our teeth and shake us to the very bone. Immediately we want to get the road crews out there smooth the rough edges. A die casting machine reacts much the same way when abrupt changes of speed are commanded. We have all seen the “chatterbumps” in the shot traces as the control struggles to obey our commands.
I can remember making barbecue lids on a machine that effectively had a one speed shot. It was necessary to trigger the fast shot almost immediately to have any chance of accelerating to the 120 inches / second needed to fill the casting. I suspect that there are still some Lesters still working out there with a two speed shot.
Having experienced lots of “chatterbumps” it is refreshing to have the capabilities of a modern control. The Visi-Trak control
http://www.visi-trak.com/Media/Vann_Proof_withAd.pdf
running the rebuilt Prince at Cana-datum has up to 6 settable speeds and 6 settable accelerations. I was an old fashioned 3 speed shot proponent until I experienced a full speed launch of a transmission case. Applying targeted smoothing of the speed transitions made it possible to move the porosity out of the seal bores.

Acceleration control solved porosity issue

Acceleration control solved porosity issue

Having been trained to improve porosity issues by tuning gate and runner shape, I was excited to discover that tweaking of the fill profile actually was helpful and a whole lot easier and quicker to implement.

Shot profile for a transmission case

Shot profile for a transmission case

Since I published this post, my contacts at Visi-Track have given me this link because it is related.
Following is a link to where you can download the Ohio State University paper called “Experimental Determination of Slow Shot Velocity Position Profile to Minimize Air Entrapment”:

http://www.diecasting.org/wcm/Technology/Technical_Archive/wcm/Technology/Technical_Archive.aspx?hkey=62f825ba-424c-41c3-b10f-3b860771ffa4

End of the Wild West

The rugged individualistic digital landscape is being fenced in

The rugged individualistic digital landscape is being fenced in


The wild west was actually a very short period of American history spanning about 40 years. We have immortalized this time because rugged individuals tamed and conquered the land. It came to a close, an organized society came in and imposed law and order and fenced in the prairies. It still remains in our hearts captured by countless books and movies.
The personal computing wild west will also span about 40 years. We are already seeing memoirs (Steve Jobs is and example) of the larger than life cowboys who roamed the plains. It will follow the pattern of every other era. When the calculators first came out spurred by the HP35 splash onto the scene, there was every imaginable version available. New and improved versions seemed to appear monthly. After a while a consensus of what a calculator should look like and what it should do emerged. Collectively we realized that it was not necessary to have a new definition of what 2+2 equals with every new release level. I remember giving my new HP45 calculator to my younger sister (also an engineer) and asking her to add 2+2. She failed because the reverse polish notation used on a HP45 makes the keystrokes 2 ENTER 2 PLUS. The modern solar cell powered calculator I use now cost $30 and has been doing the same functions as my HP (no reverse polish) for the last 15 years. The wild west in calculators came to an end.
The same evidence of the end of the personal computing wild west is showing. Open office is every bit as functional as other office suites. I suspect that we will also get tired of daily updates in operating systems that corrupt the other software that we are trying to use by separating computers dedicated to tasks from the unpredictable internet environment. Windows NT (the industrial XP version) is extremely stable as long as it is separated from the web. I suspect that hardware and software innovation which lock in program and operating systems so they cannot change will show up shortly. Yes
the wild west is being fenced in.