Automatic Products, Inc

Automatic Products wanted to improve throughput capacity by achieving greater equipment utilization and combining machining operations to minimize setup requirements, support unmanned operations, improve cycle times, and reducing overall manufacturing lead times. A big part of the challenge was in achieving balance across workstations to improve the flow of work through the manufacturing process.

Assessment
Typical jobs required multiple operations on multiple workstations, creating WIP and process sprawl as parts were batched for machining. Work processed on the two-axis lathes and vertical-machining centers required operator loading and monitoring. Per-part labor costs were excessive, and manufacturing lead times were as high as six weeks. Adding new machine capacity to the existing process would provide marginal increases in overall throughput but negatively impact individual part flow through the shop.

Solution
Ellison Technologies proposed a pair of dual spindle, dual turret, 8-axis CNC Turning Centers with milling and Y-axis. The Mori Seiki models ZT100Y and ZT1500Y include two 6,000-RPM 30HP spindles, and two 12-station turrets with 7.5HP milling capability. An integrated parts catcher with exit conveyor provides for unattended operation. Ellison Technologies Engineers provided onsite programming assistance and operator training.

End Result
The two-turret, two-spindle machines were capable of simultaneous part processing, supporting a 20% cycle time reduction. The ability to dual-tool each turret station allowed up to 48 tools to be incorporated into the machining process, allowing setup time to be reduced by 20%. The addition of a magazine load bar feeder allowed the machines to run unattended most of the time and combining milling and turning into a single machining operation, contributed to a 600% improvement in manufacturing lead times.