We have a goal to become a zero landfill waste organization by 2020.  We set it in 2010 and at the time had no idea how we were going to get there.   We generally don’t do that – set a goal without a full plan in place to get there.  However, we felt like creating waste that just sits around in a landfill was no longer the green, or lean, thing to do!

In a year we’ve done a lot to start getting us to zero waste.  We’ve converted to a full-scale Zero-Sort recycling process in which all our recyclables can go into one container.  That’s made it easier for our Associates, seriously increasing our compliance.  The Zero-Sort process has also enabled us to recycle materials we couldn’t before, like that pesky #7 plastic packaging and those #5 yogurt containers.

We have quickly realized that the best waste of all is the one that never comes into our midst.  So, now we’re on a major, multi-year project to eliminate any waste from coming to Hypertherm.  Our Supply Base Managers are busy working with our supply chain on a reusable container system and working through simple elimination or substitution of unnecessary or non-recyclable packaging.  We’re redesigning our processes to reduce waste, such as right-sizing the raw materials coming in closer to their final size.  We’ve also started a composting program in our cafeteria, soon to go full-scale.  We use metal flat ware and ceramic mugs.  We’ve raised the prices for drinks bought without a reusable container with our Zero Cup Challenge and have made those reusable containers affordable to buy.

To understand more, we conducted a full-scale trash audit for 24 hours and I wish there was a “smell” app to give you the full picture!  We learned about different materials that we’re now working hard to find a way to eliminate or to beneficially reuse with community partners.  We learned we have too many plastic bags and that we need to double-back on our Zero Sort recycling training.

In 2010, 28% of our total waste stream (by weight) was sent to the landfill.  Since we recycle a lot of metal bi-product from our machine shop, it’s more illustrative to back out the metals numbers.  Without that heavy hitter, 71% of our waste stream went to the landfill in 2010.  71% to 0% - that’s the path we’re on. 

For 2011, it’s looking like, with all the work I describe above and more, we’ve managed to get down to nearly 10% of our total weight headed to the landfill, or taking away the metals, 33% of our waste stream.  We’re excited about such a big change in our first year (from 71% to 33% of non-metals weight)!  While 33% still isn’t ZERO – we’re trying and I know we’ll get there!

-Jenny

Torch height control on a cnc plasma cutting machine…..what are the minimum requirements?

 

While you cannot purchase an industrial CNC plasma cutting machine without a torch height control system today….there are many entry level cnc machines on the market, as well as do-it-yourself homebuilt machines that are available without height control for the plasma torch. Many offer height control as an option, however for entry level users, the additional cost seems high…..and the salesman often tells the buyer that the height control is not necessary to do mechanized cutting with a plasma torch.

 

I will tell you that you can cut without a height control….but you will have to stand by the machine for every part cut, you will not experience the most consistent cut quality, and over time you will buy more torch consumables! I own two cnc plasma machines in my home shop…both have torch height control…and I would not have them any other way.

 

I thought I'd post this as it is an often misunderstood part of the CNC plasma cutting process. There are a lot of things that go on in the background of THC (Torch Height Control) with an automated plasma system....and it is a very important part of the plasma cutting process. A cutting machine without automatic torch height control will exhibit poor plasma consumable life as well as poor cut quality. Unfortunately, even with a good THC, improper settings or lack of a basic understanding of how the system works can lead to the same results as having no THC! The high end industrial torch height control systems (such as Hypertherm’s Arc Glide and Sensor THC’s) cover all of the following requirements as well as a lot more….this is my attempt to explain the bare minimum requirements that an entry level THC must be able to do for improved cut quality and consumable life.

 

Here's a simplified explanation of what has to happen for every cut cycle with a proper THC:

There are 3 cut height settings on a good quality THC. Pierce height, cut height, and arc voltage control.

1. Pierce height is preset by the operator to the plasma torch manufacturers recommended pierce height for a given material and thickness. The THC indexes down to the plate before the torch fires, locates the plate (there are a few different methods for sensing the top surface of the plate), then retracts to the pierce height. The torch then fires.....and should stay in place, no x y or z movement, until the pierce delay (recommended by the torch manufacturer for each thickness) times out.

2. Cut height is preset by the operator according to torch manufacturers recommended cut height. As soon as the pierce delay times out the torch rapidly indexes down to the cut height. At the same time x and y motion begin driving the torch through the part program.

3. Arc voltage control uses feedback from the plasma system to measure the voltage between the electrode (negative) and the plate (positive). (some call this "tip volts", which is incorrect as the torch nozzle is known as the "tip", yet it is the electrode and plate that the voltage is referenced from) At a given cut speed and fixed torch to work distance this voltage remains constant. If the plate is warped so that it moves away from the torch during steady state cutting...the arc between the electrode and the plate gets longer, a longer arc means the voltage gets higher. The torch height control see's an increase in arc voltage and signals the z axis drive to move the torch closer to the plate. Arc voltage monitoring takes over torch height functions as soon as the machine is within a certain percentage of the programmed cut speed.....so as soon as acceleration gets the machine to a certain speed...the arc voltage control takes over. Consequently when the x and y motion decelerates below this threshold percentage...the avc is disabled so the the torch does not dive during corner or small feature slowdown events .

If your torch height noticeably changes during the transition between cut height and avc, then you should adjust your arc voltage setting so that there is no change during this transition. So, if the torch indexes to cut height, starts moving, then moves further away from the plate....reduce the arc voltage setting. A rule of thumb is that 5 volts will equal approximately .020" torch movement......so reducing arc voltage by 5 volts will move the torch closer to the plate by roughly .020", increasing voltage will do the opposite.

Things that affect torch height when operating in avc (arc voltage control)

1. Gas pressure fluctuation. Changing gas pressure changes the resistance of the plasma arc, which changes the arc voltage.

2. Speed change. Slower cut speed makes the kerf wider, which means the arc is longer, which means the voltage is higher...so the THC moves the torch closer to the plate.

3. Worn electrode. Plasma electrodes wear by forming a pit in the hafnium emitter. If the pit is .020" deep, the torch will run closer to the plate by .020"....as the arc is .020" longer and the height control is trying to maintain a constant voltage.

Bottom line....the proper physical height is more important than setting the exact arc voltage that is listed in the plasma torch manufacturers manual. Adjust the voltage so the physical height is correct...don't worry about the voltage reading!

Jim Colt

Recently I traveled to Chicago, IL to participate in Hypertherm’s presence at Fabtech; a large industry tradeshow focused on the metalworking industry.  As Product Marketing Manager for the software team, I always really enjoy going to this (and other) industry shows because it gives me access to dozens of existing customers and even more potential customers; all at a single location.  I find it an efficient way to gain access to market sentiment and obtain feedback about our products.  After returning from the event, I reflected on the myriad of conversations I had while walking the show floor and working Hypertherm’s booths.  One conversation stuck in my mind.  It was a discussion I had with an attendee shopping for nesting software.  I asked the prospect what criteria he was using to make his purchase decision.  He responded confidently, stating “material utilization on the nest.”  To clarify I asked what he meant and he stated “You know.  For a full plate nest, the percentage of metal used for parts and the percentage left over [scrap].”  I’m not going to quote the entire conversation but I will explain why this is worth sharing via this blog.  You see, as a marketing guy, I want to make sure folks have all the pertinent information at hand when making a purchase decision.  After all, not only is that decision going to result in an initial software investment but the long-term implications can be immense.

In this instance, the potential buyer was focused on material savings from the software investment, which is not at all uncommon.  And I get the focus on material use, since it’s typically a significant cost element of the job; impacting how competitive the bid is or how much profit can be made on the job.  What I want to share here is there are other considerations that should be understood when benchmarking nesting software; including the impact on part quality.  For example, when nesting parts, using appropriate lead length and style and also part-to-part / part-to-plate edge separations positively impacts part quality.  While using shorter leads and reducing the separations is possible and can improve material utilization, the negative outcome to part quality is a consideration.  Lead placement on the part periphery is also a factor that impacts part quality.  Using optimal lead location may not allow parts to orient and intersect with each other as effectively on the nest and can result in a lower utilization percentage.  Also, if the nesting software is designed to nest parts first and then add leads, overall utilization may be improved but lead placement on the part periphery may be forced to locations that deliver sub-optimal part quality.  Again, the trade-off is between material utilization and part quality.  Of course, plate yield based on nest efficiency is just one aspect to consider when shopping for nesting software.  Other important considerations include ease of use, the integration of advanced cut process parameters, the vendor’s ability to support the product, among others.  So if you’re in the market for nesting software and benchmarking the alternatives, I hope this helps you in the process.



-Derek

There’s truly nothing more rewarding than being able to offer someone a job. Whether it’s our own Associates or external candidates, healthy economic times or global downturns, it’s just a great feeling when you can start a conversation with “we would like to present you with an offer…”

When I think of this statement I am reminded of a recent situation when one of our temporary employees was hired on permanently. We’ve had many temp to perm hires over the last 2 years, but this one is particularly memorable to me. For purposes of confidentiality, we will call this individual “Joe”. Thinking about his story will always bring a smile to my face.

Joe had worked at Hypertherm as a temp for 2 summers previously during his college breaks. He was young in his career but brought with him a positive attitude, good work ethic and strong team effectiveness skills. After earning his B.S. degree, we welcomed him back for a third time as a temp this past June. I should also mention that Joe quit a permanent job to come back to Hypertherm as a temp. It’s a risky move that I wouldn’t encourage, but fortunately it worked out in this case. As a fresh college graduate Joe was eager to secure a full-time, permanent position at a company he loved. That company was Hypertherm.

Over the next several months Joe engrossed himself in the recruitment process. He was interviewed for several positions but was unsuccessful in his goal of achieving permanent status. After 4 months of rejections, he became a bit more discouraged. Would his temp assignment run out before he was able to secure a permanent position? One afternoon in November, he received the news he had been anxiously waiting for all these months. Instead of being “thanked for his interest” in the position and told “another qualified candidate was selected”, he sat tensely and instead heard “we would like to present you with an offer…” His level of excitement and appreciation was almost tangible.

As a corporate recruiter, I couldn’t finish this “feel good” story without including some simple, unsolicited words of advice regarding the recruitment process: do your research about the company prior to the interview, maintain a professional demeanor throughout the entire process (phone calls, e-mail etiquette, in-person interviews, dress, etc.) and most importantly, be yourself. That’s what worked for Joe.

-Melanie

From tuners to hot rods and everything in between, car enthusiasts could find it at the 2011 SEMA (Specialty Equipment Market Association of the automobile aftermarket) Show held in Las Vegas.

Hypertherm was on the scene in the North Hall, promoting the benefits of our Powermax plasma cutting systems to the automotive enthusiasts in attendance. While a variety of fabricators and customizers took an interest in our product, it was the restorations specialists who were most enamored with the Powermax systems.

As you can imagine, restoration projects include the removal of a lot of rusty metal with numerous holes and gaps. Rusty metal can pose problems for most plasma systems because they require metal to attract the arch. When no metal exists (as is the case when cutting rusty material) the arc extinguishes, causing the user to have to re-fire the torch when the arc is back in contact with the metal. As you can imagine if you are cutting out a 4’ x 4’ rusty floor board, you will run into numerous situations where you would need to re-fire a plasma torch causing wear on your consumables and wasted time to re-fire the torch.

The Powermax system’s expanded metal cutting feature was a hit with restorations specialists, because it remedies the re-fire issue. By setting the Powermax system to the expanded metal mode and cutting through numerous rusty panels and expanded metal plates, Michael Vanvakaris (Hypertherm Distribution Sales Manager for Southern California) was able to show attendees with restorations products, how they could save time and consumables by using a Powermax to cut and remove rusty pieces without having to re-fire the torch each time they hit a gap.

You can learn more about how Powermax plasma systems can be used in the auto industry by watching our quick YouTube Video.

From everyone here at Hypertherm Cutting Institute, welcome to our new site! We’ve added new features like these:

• Forum - Finally, a place to talk about cutting metal. We've set up the framework for discussions on your projects, your equipment, and your business - where the conversation goes from there is up to you! As an added bonus, Hypertherm experts like Jim Colt will be dropping in to offer advice and answer questions from time to time, too.
• My Hypertherm Voice - If you've ever started a sentence with "I wish that Hypertherm would ___________", then this is the page for you. We're looking for your input on how to improve everything from products and services to corporate and environmental responsibility. My Hypertherm Voice is much more than a suggestion box; you can think of it more like an active brainstorming session. We don't just want your ideas, we also want you to weigh in on the ideas of others. Remember, no idea is too big or too small!
• Blog - Frequent contributions from a wide range of industry sources will make this section of the site a great place to add to your Favorites. As a registered user, you can also participate in polls and comment on blog entries.
• Enhanced training content - Our collection of high definition videos stream faster than ever. Add even more interactive e-learning courses and valuable print-outs to the mix, and it's easy to see why our training materials are getting a lot of industry attention!

As a site administrator, it is my job to be a resource for you. I want to make sure that Hypertherm Cutting Institute is an effective social and training tool. Once you've given the new site a test drive, come back and tell me what you think in the comments section!

-Jesse