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.

1. AUTOMATION & INTEGRATION:
MACHINING TO THE MAX
Effective Process Automation & Integration
for Lowering Your Cost of Manufacturing

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. Principles of Effective Automation Implementation
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•
•
•
Project Management
Project Engineering
Site Supervision
Post-Installation Support

4. Principles of Effective Automation Implementation
• Project Management
– Single point of contact
– Commercial
management / vendors
– Tracking and reporting
schedule
– Change management

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. 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. Principles of Automation Technologies
•
•
•
•
Machine tool
Software
Manufacturing process
Integration

8. Principles of Automation Technologies
• Machine tool
– History of exceptional
reliability
– Quick Platform
– Flexible / agile for
“retool”
– “Open” to integration

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. 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. Principles of Automation Technologies
• Robot interface
considerations
– Machine side informational
screens
– Manual load mode
– Automated load mode

12. Single Point of Control – Cell Controller
MACHINE
STATUS
MESSAGES
ROBOT
STATUS
MESSAGES
ALARM
MESSAGES
SYSTEM
DOCUMENTS
ROBOT
CONTROL
PART
COUNTER

13. Single Point of Control – Cell Controller
MACHINE
UNLOAD/LOAD
REQUIREMENT
STATUS
MACHINE
GAUGE
CYCLE
COUNTER
MACHINE
PART
STATUS

14. Single Point of Control – Cell Controller
ROBOT
STATUS

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. Effective Process Automation
Real Case Studies

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. 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. 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. 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. 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. 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. Real Case Studies:
Steering Gear Housing Machining
• Application
– Aluminum
– 2 Operations
– 12 fixtures
• Integration
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–
–
–
6 HMC’s
Gantry Robot
Pallet Conveyor
Part Washer
• Bottom Lines
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–
–
–
(6) machines, (1) operator
Continuous production
Guarding allows machine access during robot operation
Improved part quality with “Live hydraulics” fixture
VIDEO

24. Real Case Studies:
Steering Knuckle Machining
• Application
– Cast Steel
– 3 Operations
– 1 Fixture
• Integration
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–
–
–
–
3 HMC’s
Fanuc Robot
Pallet Conveyor
Telesis Marker
Part deburr stand
• Bottom Lines
– Single sourced
– Improved efficiency
A
C
B

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. 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
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–
–
–
Parts wash stations
Part marking stations
Gaging, off-line and in-line
Sub-assembly and special
machining stations

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. Effective Automation & Integration
• End Results:
– Reduce manufacturing cost
– Reduce labor and manual intervention
– Improve part quality
– Improve flexibility of capital assets
– Increase manufacturing efficiency