Olympic Arms

Olympic had a long history of component outsourcing in response to capacity limitations. As the business grew, component outsourcing became a limiting factor to predictable and timely delivery of finished products. The inability to control outsourced activity also complicated new product innovation due to the integrated nature of product design. Management determined that bringing all component manufacturing in house would be necessary to strengthening product quality and time to market advantages.

Assessment
Many of the outsourced components were complex, requiring multiple operations across different work centers. Management wanted to implement a “once & done” process that would take raw material to a finished part in a single operation at substantially less cost than that of current outsourced suppliers. This would require the minimization of setups, optimal equipment utilization, and unmanned machining to reduce labor content.

Solution
Ellison Technologies configured a solution that allows for component manufacturing in a “once & done” process, utilizing a Mori Seiki model MT253S/1000 Integrated Turning Center with hand-off capability permitting automated front-side/back-side machining. In addition, a turning/milling head with 4-axis movement performs all machining operations in a single process. A bar feeder and custom designed part unloader allowes the system to run in unattended mode with full lights out manufacturing on the third shift.

End Result
Olympic has completed the process of bringing outsourced components in house. A 50% reduction in component costs and 30% throughput gains are allowing them to accept orders they could not have taken in the past. Their ability to respond to customer needs has improved due to increased manufacturing flexibility and the reduction in time to market for new products due to improved turn around time in rapid prototyping.