Muse Metal Laboratories, Inc

The existing method of manufacturing featured CNC lathes and machining centers situated around a sophisticated quality control center, allowing parts to be checked efficiently as they move from one operation to the next. This system was designed to efficiently process lot sizes ranging from 25 to 100 pieces. Muse was offered a contract to manufacture the same difficult components in lot sizes of 500-1000. This created the challenge of maintaining component quality and unit cost at increased production rates.

Assessment
Muse considered maintaining the same manufacturing approach and simply adding to the existing capacity of 2 axis lathes and 3 axis vertical machining centers with 4th axis capability. This would require operators to both run and set up the machines, a challenge given the short supply of qualified personnel capable of programming and setting up machines due to the part complexity. Management turned their attention to evaluating multi-process technology capable of machining multiple part features in a single set up.

Solution
Ellison Technologies evaluated the throughput and technical requirements of the manufacturing process at higher volumes, giving consideration to work envelope, tools, horsepower and RPM requirements. They recommended and integrated a Mori Seiki NL2500Y turning center with milling capabilities, Y-axis travel and a full C-axis in the spindle.

End Result
The Mori Seiki lathe offered improved accuracy at higher feed rates and spindle speeds. The ability to perform both turning and milling operations in a single set-up improved labor efficiency and part quality. Exceptional size control, surface finish, concentricity, roundness and repeatability reduced or eliminated secondary operations. Operator requirements were reduced by 40% and throughput increased primarily due to reduction in part wait time moving between machine operations and reduction of secondary operations.