The term flexible workcell often conjures up an image of an automated automotive manufacturing line where machines are changed in and out depending on the part being made. In aerospace or semiconductor facilities, where regulations and specifications are more fixed, flexible workcells are a bit more complicated, but they can be created by working closely with a machine tool supplier to develop a long-term plan.
Mitsui Seiki builds machine tools to fit specific jobs. We collaborate with customers from the outset, often finding new ways of machining a part or parts simply because we’ve seen it done before elsewhere and know the technology well.
One current customer envisions a large workcell comprised of many machines and is attached to a pallet-loading system. Rather than building several machines all at once, it’s better to determine the customer’s final goals and work backwards to develop a machine tool upon which the entire system will be based.
For aerospace manufacturers, many of which produce small batches of the same part built to tight tolerances and stringent, unchanging specifications, flexibility isn’t the first or even the second consideration when buying a machine tool. However, sometimes a customer no longer requires Part A and needs Part B almost immediately. This is where the high-precision, fully automated workcell pays for itself.
As an example, a machine tool with a large tool capacity magazine can be combined with a large pallet pool, such as a Fastems system, that can provide the flexibility to change up the parts needed to run on the machine based on demand. Even though you may have a strictly controlled parts process, machines that can pull from pallets in the tooling allow for great flexibility depending on customer needs. Significant time and sweat can be saved when fixtures, tooling and raw materials specific to Part B are automatically ready and loaded into the machine for quick operations.
This is vastly different from old school thinking that dictates there are a lot of stand-alone machines available to change up a part. Pallets and fixtures for Part A were manually pulled and the new pallets, fixtures and tooling were manually loaded in. It’s a task that could take a couple of days from loading to proving out the process.
With the new pallet systems on several machines, machining flexibility is at a new level. We ask: “What does my customer need?” and then draw up a system that can take minutes to change everything out.
Working closely with a machine tool provider is the best way to ensure the machine will run 24/7 for years to come. It’s important to have a machine that is extremely accurate to minimize—or eliminate—issues with “wandering” tolerances while running lights out. It’s possible to build that high-performance machine dedicated to producing a specific part and have the flexibility to adjust the number of runs or materials used. A custom-built machine, or one modified according to customer needs, makes no compromises on spindles used, travel or machine tolerances.
Machining for the aerospace, semiconductor and other precision-dependent industries requires customization for even the smallest batches. Combining these tailor-made, high-precision machines with a fully automated pallet system creates a powerful workcell with the flexibility required in today’s manufacturing environment with the precision necessary to meet the stringent specifications demanded by the industries shops serve.
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