Machining Automation and Integration to the Max

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This presentation on “Machining Automation and Integration to the Max” has been adapted from Makino’s webinar series. To view the full webinar, visit http://www.makino.com/resources/webinars/archive/automation-and-integration-machining-to-the-max/319/

Machining automation is a proven method for reducing manufacturing costs, eliminating non-value added labor, improving quality, increasing equipment flexibility and growing throughput. This presentation discusses the fundamentals of machining automation, key activities performed during implementation, and the technologies involved to complete a successful automated system. An emphasis on project management and engineering is discussed, providing insights for successful installation of machining centers, software and the manufacturing processes that drive North American manufacturing success. The discussion concludes with a series of real-world case studies from shops that have successfully integrated machining automation to lower their overall cost of manufacturing.

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Machining Automation and Integration to the Max

  1. 1. AUTOMATION & INTEGRATION: MACHINING TO THE MAX Effective Process Automation & Integration for Lowering Your Cost of Manufacturing
  2. 2. Automated Manufacturing • Why companies are embracing and expanding automated manufacturing process: – The global economy – Fierce pricing pressures – Reduce labor costs – Yet, remain flexible enough to adapt quickly to changing volumes and designs
  3. 3. Principles of Effective Automation Implementation • • • • Project Management Project Engineering Site Supervision Post-Installation Support
  4. 4. Principles of Effective Automation Implementation • Project Management – Single point of contact – Commercial management / vendors – Tracking and reporting schedule – Change management
  5. 5. Principles of Effective Automation Implementation • Project Engineering – Mechanical, controls, & software engineering – Specifications development – Drawing approvals – System runoff support at Makino & at customer – Final documentation
  6. 6. Principles of Effective Automation Implementation • On-Site supervision – Installation activities – Single point of communication – Manage schedules • Post-Installation support – Smooth transition into full production – Training and troubleshooting – Culture change
  7. 7. Principles of Automation Technologies • • • • Machine tool Software Manufacturing process Integration
  8. 8. Principles of Automation Technologies • Machine tool – History of exceptional reliability – Quick Platform – Flexible / agile for “retool” – “Open” to integration
  9. 9. Principles of Automation Technologies • Software considerations – Part status tracking • Part ID input from automation • Communication from machine to automation – Automated inspection logic • Tool monitoring and auto spare tool selection • Signal to inspect part after a tool is used for the first time – Error checking • Proper seating of part to fixture • Proper seating of part/pallet to machine tool • Automatic verification of tool data
  10. 10. Principles of Automation Technologies • Manufacturing Process – Part process must be oriented to automation • Balanced operations/flow • Method of tracking part status – Fixture design must be oriented to automation • • • • • • Design for robot load Part presence detection Part seated detection (air) Chip control/shedding Rest pad coolant wash Fixture flush
  11. 11. Principles of Automation Technologies • Robot interface considerations – Machine side informational screens – Manual load mode – Automated load mode
  12. 12. Single Point of Control – Cell Controller MACHINE STATUS MESSAGES ROBOT STATUS MESSAGES ALARM MESSAGES SYSTEM DOCUMENTS ROBOT CONTROL PART COUNTER
  13. 13. Single Point of Control – Cell Controller MACHINE UNLOAD/LOAD REQUIREMENT STATUS MACHINE GAUGE CYCLE COUNTER MACHINE PART STATUS
  14. 14. Single Point of Control – Cell Controller ROBOT STATUS
  15. 15. Single Point of Operator Interface Cell Controller • Cell Status Overview • Robot Control • Safety Fence Access Control • Gauge Cycle Counters • Cell Runout • Part Type Select • Part Information Tracking • Material Handling Control
  16. 16. Effective Process Automation Real Case Studies
  17. 17. Real Case Studies: Compressor Manifold Machining • Application – Aluminum – 2 Operations – 4 Fixtures • Integration – 2 HMC’s – Material Handling – Overhead Robot on rail • Key success factors – Reduced labor – Increased throughput – Increased efficiency
  18. 18. Real Case Studies: Cylinder Head Machining • Application – Aluminum – 2 Operations – 18 Fixtures • Integration – Overhead Gantry – Facility specific mods • Key Success factors – Capital efficiency (redeployed) – Increased efficiency (value-add time) – Add operations without added labor (xfer line expansion) – Continuous production even if machine is down
  19. 19. Real Case Studies: Cylinder Head Machining • Application – Aluminum – 4 Makino + 17 operations – 22 Fixtures • Integration – – – – – – – – – 15 HMC’s Zone Conveyor Washers Seat & guide assembly Cam Boring Gantry Robot Central Coolant Leak test Brush deburr
  20. 20. Real Case Studies: Cylinder Head Machining • Key success factors – Increased value add – Increased agility • Multiple head configurations – Single sourced – Technology transfer • Culture shift/training
  21. 21. Real Case Studies: Large Cylinder Head Machining • Application – Cast Iron – 1 Operation – 4 Fixtures • Integration – 2 HMC’s – Fanuc Robot • Key Success Factors – Expanded an existing dedicated line – Add flexibility – Add operation without adding labor
  22. 22. Real Case Studies: Oil Rail/Rocker Arm Carrier Machining • Application – Cast Iron – 2 operations – 56 fixtures • Integration – 12 HMC’s – Gantry Robot – Pallet Conveyor • Bottom Lines – Agile: part changed one year later – Low cost “re-tool” – Transferred “know-how” for high volume manufacturing VIDEO
  23. 23. Real Case Studies: Steering Gear Housing Machining • Application – Aluminum – 2 Operations – 12 fixtures • Integration – – – – 6 HMC’s Gantry Robot Pallet Conveyor Part Washer • Bottom Lines – – – – (6) machines, (1) operator Continuous production Guarding allows machine access during robot operation Improved part quality with “Live hydraulics” fixture VIDEO
  24. 24. Real Case Studies: Steering Knuckle Machining • Application – Cast Steel – 3 Operations – 1 Fixture • Integration – – – – – 3 HMC’s Fanuc Robot Pallet Conveyor Telesis Marker Part deburr stand • Bottom Lines – Single sourced – Improved efficiency A C B
  25. 25. Real Case Studies: Engine Block Machining • Application – Aluminum – 1 Operation – 2 Fixtures • Integration – Fanuc Robot – Custom front-end – Engineering - gripper • Bottom Lines – Added operation to existing “line” – No added labor cost VIDEO
  26. 26. Makino Integration Services • Makino integrated systems can include: – Makino machining centers – Automated material handling • Makino MMC system • Gantry, pedestal robotic load/unload systems • Part conveyance – – – – Parts wash stations Part marking stations Gaging, off-line and in-line Sub-assembly and special machining stations
  27. 27. Makino Turnkey & Integration Facilities • “Best-In-Class” manufacturing systems integration facility • 150,000 square feet dedicated to execution of customer specific turnkey & integration projects • Supports all turnkey and integration activities of Makino and third party equipment
  28. 28. Effective Automation & Integration • End Results: – Reduce manufacturing cost – Reduce labor and manual intervention – Improve part quality – Improve flexibility of capital assets – Increase manufacturing efficiency

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