Pazmac Enterprises Ltd

Pazmac faced a pressing demand from customers to increase manufacturing capacity and accept an increasing volume of work. The challenge meant they needed to achieve this with no increase in floor space or head count. Additionally, they needed to improve lot to lot process & setup repeatability machining complex parts.

Assessment
Previous process involved multiple single operation machining processes spread across a variety of stand-alone machine tools. The machines consisted of 3&4 axis vertical machining centers and 2-axis turning centers. These machines required constant setup activities as this customer batch processed small lot sizes. Some workpieces required circular process route from lathe to mill and back to lathe, causing additional process sprawl.

Solution
The solution hardware provided consisted of a Mori Seiki model MT2000SZ 9-axis integrated turning center. This machine provides a 4-axis tool changing milling/turning head with a 180-tool magazine, a 12-position lower turret, and sub spindle. Ellison Technologies provided initial process concept, process time studies, economic justification and final proof of concept run-off at customer’s facility. Ellison also provided extensive customer training for both operation and programming.

End Result
Customer reports their setup time was reduced by 75%. Revenue per man increased 3 to 1. Payback – 2.5 years. Work in Process – 100% improvement. Inventory – 50% reduction. Throughput (in revenue) – 300% increase. Customer Satisfaction – 400% increase in backlog. Customer Response – 200% improvement in On Time Deliveries.