Production Machining - Your access to the precision machining industrial buyer.
Issue link: https://pm.epubxp.com/i/739833
Its customers include companies in the transportation, aerospace, medical, defense and energy industries. Annual volume is $12 million. One of the high volume parts the company produces is a series of aluminum end caps for carbon fiber compressed natural gas (CNG) tanks. ese "return to base" tanks carry fuel for buses, trucks and other vehicles that tradition- ally run on diesel or gasoline. CNG is a greener, cleaner burning alternative fuel that creates less pollution. When Mr. Arant took a close look at the manufacturing process for these parts, he identified it as an opportunity to convert the existing approach to robotic automation. Using value streaming and lean principles, he documented every step of the existing manufacturing process, from raw materials through machining, inspec- tion and preparation for shipping. "I decided to take the approach that everything we were currently doing to make these parts was wrong. is helped me look at the job with fresh eyes. Instead of simply trying to improve the process we already had, we rethought our entire approach to see how we could make these parts much more efficiently." e existing process began with receipt of barstock that Northeast Tool would saw to size, load into the first machine tool to rough, turn one end and then set aside for batching. When a batch of parts was ready, each part would be individually loaded into additional machines for further processing, which included a polishing machine to achieve the required surface finish. Because of all of the handling in and out of machines, the parts often had to be re-polished to meet specifications. What Mr. Arant discovered was that each part traveled the equivalent of one mile throughout his facility, from start to finish. e entire process required three CNC lathes, two milling opera- tions, polishing, washing and inspections after each operation. roughout this journey, at least 15 people touched the part during the course of two and one-half shifts. ese touches included sawing and stacking barstock on pallets, machining, counting, batching, washing, inspecting and shipping. Recognizing that every touch adds cost to a part, Mr. Arant knew he needed a less hands-on process. Looking for a turnkey solution, Mr. Arant began talking to suppliers to identify a company that had the capability to combine machining, inspection and automation. "I wanted a system that would integrate everything from raw materials to finished parts and could be attended by a single machine operator. I talked to a number of suppliers, but did not find what I was looking for until Okuma dealer Morris South brought in Gosiger Automation. ey listened to what I wanted to achieve and came back with a plan that checked all of my boxes." As a result, the company now needs only 4 minutes, 51 seconds to make (from raw stock to out the door) aluminum CNG tank end caps that previously took 39 minutes, 21 seconds to complete. Not only is this a huge time savings, it also frees up considerable floor space that was occupied by the additional 14 people, tools and working space that the former system required. Northeast Tool then had the ability to add more machines to expand capacity and repurpose people to other jobs. e automation system designed by Gosiger Automation consists of one FANUC R-2000iB/165F six-axis industrial robot positioned in the center of three Okuma LB-3000EX-MY lathes arranged in a semi-circle. A floor-mounted pallet locator positions a pallet holding workpieces delivered by a lift truck. e family of parts consists of 17 distinct end caps made from blanks that :: Before implementing the turnkey solution, the production process required three CNC lathes, two milling operations, polishing, washing and inspections after each operation. Robotic Automation productionmachining.com :: 37