I had the opportunity to take a tour of Sikorsky Aircraft in Stratford CT yesterday. What a great experience.!
They had one machine that was a six axis mill which had so many pallets that could be loaded with parts I think it could run for a week (maybe a slight exaggeration) unattended.
Their gear department (they make all their own gears) had the latest in gear hobbing, shaping and grinding equi[pment. I had nice chats with several of the machinists and was able to recall more than I would have thought from my gear manufacturing days when I was an apprentice lad in the middle '60's.
Most of their work is now arranged in "cells" that allow the work pieces to progress from one operation to the next with a minimum of handling and delay.
At one machine we were shown the raw forging that was being worked on. The price of the forging alone was about $60,000 and the finished value of the part was over $160,000. Certainly not the place for a misplaced comma or other blip in the programming. Last year they scrapped one piece out when it was about at the $100,000 level of completion. Ouch!
The entire shop was spotlessly clean and one of the area supervisors told us that one of the things they are very big on is cleanliness and organization. Most machines had custom fitted tool trays with the wrenches that the machinist would need to perform the tasks at hand.
On the assembly floor I saw Blackhawk helicopters in various stages of assembly. There is an astonishing amount of wiring that goes behind the interior panels in one of those crafts. Everything has to be just so and the interior is cleaned with small hand vacuums several times a shift to ensure that no chips or dirt is left behind to chafe the wiring after the sections are closed up.
It was GREAT to be, if only for a few hours, in an atmosphere where fine work is being done, the workers take great pride in their jobs and everyone seemed aware that their part of the overall effort was important.
I know that my students are "only kids" and don't, indeed can't, have the maturity and skill to do that sort of work, at least not yet, but there are days when the stupidity of adolescence gets me down.
It was great to have a day out in the real world where adults are doing nice (and important) work.
Errol Groff
Instructor, Machine Tool Department H.H. Ellis Regional Technical School Danielson, CT 06239
860 774 8511 x1811