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Rapid Tool Development
What OKAY has done to make RAPID TOOLING possible
is to provide the latest in equipment, technologically innovative
software, and a compatible design/build process to its already
knowledgeable designers, toolmakers, and quality engineers.
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OKAY's primary engineering software is
AutoCAD (and AutoCAD Inventor) for Windows with several
proprietary software enhancements that virtually produce
detailed drawings and the die set design automatically
from the competed tool assembly design. The engineering
software operates on networked Pentium PC's.
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OKAY's engineering database is utilized to translate work instructions
for the Wire EDM machines and CNC vertical machining center through
NC software. The way OKAYis utilizing this CAM software, programming
for large blocks of tool steel, incorporating many details can
be accomplished in a matter of minutes vs. 6-8 hours with previous
methods.
 To achieve this RAPID TOOLING capability, we first had to create
an environment that utilized all of our technical expertise.
Rather than the traditional approach of a design engineer designing
in a vacuum without input, we chose to form a consensus with
all those involved in the building and production end of the
program as well.
Next, we designed an array of reusable tooling to perform designed
experiments that proved out tooling concepts and produced real
development data that could be used in the final design with
known results rather than theoretical "guestimates." Utilizing
designed experiments has clearly reduced de-bugging time by as
much as 70%.
After creating a team oriented atmosphere where everyone, from
design engineer to production machine operator, has a stake in
the success or failure of each design, the benefits were twofold.
We realized better designs and less expensive tooling.
We focused on customizing our CAD software to generate designs
that would be modular and flexible so that off the shelf tooling
components could be utilized with minimal alterations. Another
benefit is that 30% - 40% of RAPID TOOLING components can be
utilized in production tooling, reducing the cost of production
tools significantly. In addition, utilizing "hard tooling" components
in prototype tooling demonstrates production capability on critical
features.
By refining our software for design and CNC programming, we
have been able to begin a design and start cutting steel within
hours, rather than days, after the start of the project. Having
the capacity to universally alter a design in minutes has given
our customers the advantage of quick, cost effective design changes
without negative impact on delivery schedules.
The critical factor in a RAPID TOOLING program is to make the
first tryout part as close as possible to specifications, followed
by predetermined tooling changes to bring the part to print.
OKAY's design/build process has evolved to incorporate the following
steps:
(1) A design review (potential problem identification.) (2)
Up front R&D of potential problems. (3) Establishing a tool
development strategy. (4) Finalizing die assembly design and
detailing concurrent with beginning machining. (5) Completion
of components and assembly. (6) Analyzing the first tryout part
against specification and implementing the development strategy.
 The last element of OKAY's RAPID TOOLING development process
is quick and accurate inspection feedback. By utilizing its RAM
Optical CNC vision inspection system, OKAY's quality engineers
can preprogram from the part print (in digital form) how each
feature is to be measured.
When the first tryout part is submitted, the inspection is completed
in minutes, including a complete inspection report. In addition,
the digital data is converted back to AutoCAD to compare actual
vs. specification and to plan the next development tool changes.
The many benefits of OKAY RAPID TOOLING are being seen in the
Automotive, Medical/Surgical, Defense/Firearms, and General Industrial
markets.
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