Manufacturer Takes Innovative Approach To Advanced Manufacturing Processes

Commodity parts (shafts, arbors, bearing races, gear splines, etc.) must be produced faster and less expensively to survive in the present maket environment. Precision Group Inc. (PGI) of Rockford IL has developed the Team Key concept using robots to lower labor costs and advanced machine tools runn...

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Bibliographic Details
Published in:Modern machine shop 2000-05, Vol.72 (12), p.168
Main Authors: Jordon, John M, Kelley, Katherine A
Format: Magazinearticle
Language:English
Subjects:
Commodities
Machine shops
Machinery industry
Manufacturing
Metal products industry
Pallets
Production management
Robots
Tool industry
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Summary:Commodity parts (shafts, arbors, bearing races, gear splines, etc.) must be produced faster and less expensively to survive in the present maket environment. Precision Group Inc. (PGI) of Rockford IL has developed the Team Key concept using robots to lower labor costs and advanced machine tools running on a 22 hour, 7 days a week production schedule. PGI was unable to to handle the increased production with single-spindle CNC lathes, so they began a search for the required advanced machine tools, selecting three new Mazak Multiplex 630 twin-spindle/twin-turret, multitasking, turning centers with live tooling (for milling, drilling and tapping) from Mazak (Florence KT). PGI also purchased the Integrated robot part handling (Mazak GL-200 Gantry Robot Loader /Unloader system). PGI consolidated the new line into a 3,500 sq ft area to assure efficient workflow. Raw parts are brought in and placed upon special pallets which are loaded into the machines where robot handling delivers the pallets to the spindle while delivering finished parts back to the pallet. The cut parts are deburred and sent out for heat treating and then returned and ground to final tolerances. The Mazak Multiplex 630 offers all the capability of a vertical machining center and a lathe in a single unit and can machine both sides of a part with an automatic in-machine hand-off to the second spindle. Keeping the parts in one machine is important since this avoids secondary operations. If part modification or redesign is needed all it requires is a program change so there is no need to redesign and build new fixtures. Production has increased by 30% due to higher throughput. A 10-hp rotary spindle motor on the turret can produce speeds up to 1,500 rpm offering equivalent performance comparable to a machining center for secondary operations.
ISSN:0026-8003