Industry: Aerospace, Automotive, and IndustrialProcess: Turning and Milling | Before | After |
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| • Labor Intensive
• Multiple Machines per part
• Poor quality due to multiple set ups
| • One operator produces 10X as much
• Operations combined on one machine
• 60% reduction in part handling
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The system allows 4 hours of unattended operation, increasing production capacity 4 hours per day. Part loading time was reduced to 15 seconds and setups were cut in half. Overall machining cycle times were reduced by 50%, and the combining of two machi [...] Read more »
Industry: Precision Machining Sub Contractor
Process: Multi-Process Machining | Before | After |
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•Labor intensive process
•Low profit parts
•4 operations with 4 set ups
•Three week lead time
| •Unmanned cell operation
•Most profitable parts
•2 operations and 2 set ups
•93% reduction in lead time
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The move to multi-process technology reduced machining cycle times by 75% and eliminated 90% of the labor requirement. It compressed manufacturing lead-time from 3 weeks to 1 ½ days, and eliminated 50% of the set ups and part touches. Together with the [...] Read more »
Industry: Heavy Truck, Medical, Aircraft & Recreational equipment manufacturers
Process: Multi-Axis Production Turning | Before | After |
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• 6 week delivery
• Labor intensive process
• Constrained by capacity
• High manufacturing costs
| • 4.5 day delivery
• 90% reduction in per-part labor costs
• 50% increase in throughput
• Operating margins doubled
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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 tim [...] Read more »
Industry: Lawn and turf, recreational, and power generation
Process: Oil Pan Machining Vertical M/C | Before | After |
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•Multiple set ups and part touches
•Difficult to maintain feature quality
•Significant WIP inventory
| •Single process operation
•1.67 Ppk quality on critical features
•Best-in -class cycle time at 4.3 minutes
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The solution allowed the part to be completed in a single operation, while meeting the 1.67Ppk requirement on critical features. The cycle time exceeded requirements at 4.3 minutes, including a part load /unload time of just under 5 seconds. [...] Read more »
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