Growing a machine shop takes vision. And Tyler Stilson’s eyesight is 20/20.
His job shop, Frederick, Colorado-based Operose Manufacturing, produces a wide range of products, from fluid control mechanisms to commonplace sporting goods. They handle complex machining jobs from prototyping to large-scale production runs.
When he founded the company in 2007, Stilson had one mill and one lathe. However, he envisioned a more dynamic business and sought a partner that would help him achieve his vision, including a pathway into 5-axis machining. He needed to achieve intricate features on different angles that required offsets, small-tapped holes, winding tool paths, and careful workholding.
But he had many questions. Stilson wasn’t familiar with 5-axis programming or software. He wasn’t sure if he needed simultaneous 5-axis machining or if 3+2 was the right choice.
So, he reached out to Methods Machine Tools.
One of the shop’s first forays into 5-axis machining came in the form of a rotary table on an existing FANUC RoboDrill, sold and serviced by Methods.
“In less than two weeks, we reached the same conclusion – we needed to figure out how to do this again,” Stilson said. “Getting at the parts with a 5-axis machine was incredible. We saw huge opportunities to save money and improve our quality.”
Now tasked with meeting the demands of high-volume production, Operose was one step closer to automation, equipped with new machining capabilities such as a tool spindle, lower turret, and 72 tool stations.
The Methods Plus K rotary storage carousel features 60 part/part carrier positions this is for the photo with the arm
In the fall of 2019, Stilson sought to test out equipment at company’s second workshop in Mankato, Minnesota. Since it was an at-home lab, he needed the ability to load up a cell in the morning and collect perfect parts at the end of the day.
Given the size of the workshop and his preference for RoboDrill’s ease of use and adaptability, the choice was simple: the Methods Automation Plus-K.
The Plus-K, which integrates with the RoboDrill, measures just 32 inches wide, making it ideal for Stilson’s shop. Methods enabled the robot to recognize a standard feature on the quick-change carrier, eliminating the need to program the robot.
“That’s what made me go with the Plus-K— having the ability to load it and go do something else,” he said. “And I know RoboDrills, I love RoboDrills. The Plus-K’s 60 tools or 60 pallets is pretty appealing.”
The first system was installed in Mankato in April 2020. The second followed in the Colorado Shop in January of 2021, and the third was installed three months later. They produced aerospace and medical parts made from stainless steel or aluminum.
“Part of what made it stand out was the footprint,” Stilson said. “I don’t know how thick my floor is [in Mankato], and there are a lot of unknowns. I know a lot about the RoboDrill, I know it will fit. I know if I want to add more, they can fit in this shop, and I know people can use one machine, one control, and become extremely productive.”
“The Plus-K is a much better system, because it has 5 axes, 60 tools and takes about 15 minutes to learn inside and out.”
Operose has grown exponentially since implementing a rotary table more than a decade ago. One innovative piece of technology led to another, another, and another, allowing the shop to take on new challenges.
Thanks to automation and 5-axis technology, Operose now approaches traditional job-shop work with a more competitive edge and take on medium-volume production runs.
Visit methodsmachine.com to learn more about solutions to fit your business.
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