Specific Skill Keyword About Steven Heidtke computer-aided manufacturing numerically controlled machine tool Steve began using CAM in its earliest stages, using Compact II and DataCut to create machine instructions for Numerically Controlled (NC) Machine Tools. He advanced to writing scripts and macros in Automatically Programmed Tools (APT) language to perform machining functions around canonically defined geometry. Using Computer Aided Manufacturing (CAM) Systems with Graphical User Interface (GUI) and Computer Aided Drafting (CAD) integration, Steve has productively generated fully verified, crash-free and geometrically correct, machine code, reducing the Total Cycle Time to produce a part. Throughout the past 20+ years Steve has used several CAD/CAM systems to program a wide range of parts and machinery in both high-mix and high-volume manufacturing plants. He has defined piece part geometry using CAD wireframes and surfaces, and created toolpath for some of the most complex parts, including advanced supersonic aeropace jet engine cases and structural members. The methods he uses takes advantage of the CAD/CAM/CNC system and post -processors to deliver geometry correct and verifiable in the toolpath to the machine tool with minimal operator intervention, such as edits or repositioning of the workpiece.   lean manufacturing Steve has used Lean Manufacturing techniques since learning about it in 1985. Most recently he became a Certified Lean Six Sigma Black Belt. Steve was a member of a team that transformed Briggs & Stratton into Focused Factories using the Toyota Production System (TPS). Within two years Briggs & Stratton increased inventory turnover rate from 2 to 200, and slashed lead time from 6 months to 24 hours. Steve has incorporated lean tools such as Kanban, one-piece-flow, and SMED into innumerable projects and maintains a focus on Total Cycle Time.   machine installation Steve shipped and installed several machine tools and systems worth up to $18,000,000, from machines that weigh several hunderd pounds to 100 kips, and in a range of technologies from welding gantries to precision machining centers to packaging equipment. He understands industry practice and leads installation projects working with riggers, mechanics, electricians, programmers, operators, etc., and trains people on the new equipment. Installations included complete Focused Factory layouts, machining cells, and individual machines. Steve has created factory building and plant floor layout drawings using CAD and has examples of transmittal documentation showing the phases of machinery moves needed to complete a project. Steve is experienced with forklifts, cranes, and many other tools reducing the need to schedule multiple resources.   machine-tool code Steve has been writing machine tool code since Flexo-Writers were used to punch ASCII 8-bit code on 1 inch paper tape, then spooled on the machine thru the tape reader. Steve wrote code in several unique languages of machine code including Fanuc Custom Macro, Kearney & Trecker APL, and Okuma User Task 2. The programs are used for performing functions such as probing, tool measurement, tool life management, and specialized production requirements. Other types of coding include sub-routines, safe-start-blocks, and post-processor development to insure correct and safe code from the CAD/CAM system.   machine-tool qualification machine-tool runoff precision machine tool Steve developed and performed machine tool qualification and machine tool runoff procedures for Caterpillar, Ingersol-Rand, Briggs & Stratton, MTS Systems, and others in the aerospace, nuclear, defense, & heavy equipment industries. Often these procedures are required for reliability and/or precision machine tool applications. These procedures range from demonstration of geometric accuracy, to Process Capability Index (CPk) studies during runoff on turn-key systems. Steve placed a calibration artifact into service on a large FMS that was scheduled to run automated inspections of the machine tool accuracies and report pass / fail and quantitative analysis for each of over a dozen large machines. Successful qualification procedures are a critical milestone in the delivery of machine tool systems, often linked to the largest percentage of progress payments, and frequently the last step before a machine is put into full production. Criteria for qualification and acceptance by the customer are clearly defined in the contract terms, which frequently is in the form of a proposal by the supplier and a purchase order from the customer. These documents often have differring terms and conditions that are overlooked in the haste of a new order. Terms of acceptance that are not clearly defined can result in a serious point of contention between parties, affecting all stakeholders. Steve has helped resolve misunderstandings resulting from changes of scope, misinterpretations of standards, and performance failures of the machine tool to meet specifications.   machining tool and fixture design Steve learned to design fixtures, tools, and gages in a shop with 1000 different types of machine tools, including plain mills and machining centers. Steve designs fixtures and tools using CAD/CAM during the process planning phase of piece part development. First the finished part geometry is imported or created, a tool list is defined, and each feature is accounted for in the machining process on a blueprint. A sequence of operations is defined from the most difficult finishing operations and working backward through the process to raw stock. Operations are defined in sequence, and fixture concepts are developed along with stock allowances and tool clearances. Machining fixtures require: modeling along with piece parts; detailed and dimensioned isometric drawings; Bill Of Material (BOM); manufacturing instructions; tool lists; and toolpath (CNC machine code).   welding machinery Steve has been welding since the 1970's on everything from motorcycles, cars, and heavy vehicles, to machine guns, aircraft engines, and fuselages, Welding machinery either: replaces a human being; or presents forces, action, and environment beyond our capability. Replicating human effort requires knowing how to perform the task, then teaching a machine to give the same result within it's operating scope. Steve has demonstrated the ability to weld alloy steels and develop the fixtures, parameter settings, metallurgical qualification records, procedures, and programming for a fully automatic robotic welder. This system Gas Metal Arc Welded (GMAW) several subassemblies for a 40mm Navy machine gun. Steve used the Spray Arc Method (using an atomized particle spray) and the Globular Transfer Method on the same machine with several welding operations. At MTS Systems Steve was a design team member for a large Friction Stir Welding (FSW) system for a commercial aircraft builder. The model shop he supervised helped build a proof-of-concept machine and tooling. The final machine used a 3-axis gantry machine that Steve wrote specifications for and supervised the geometric qualification testing giving acceptance to the project engineer. Steve also gave direction to the mechanical engineer designing the 4th and 5th axis head / spindle, basing recomendations on machine building standards, structural integrity, and practical knowledge of manufacturing the major components. Steve's MTS team helped build a similar concept and full scale Linear Friction Welding (LFW) machine to make near-net shape turbine engine blades for Rolls Royce.