The boring and milling machine used by Ace can prepare mold bases for other machines that manufacture welded die forgings. The company claims that this machine also has many other features that can help support the entire production process.
All production plants that are ready to start working on fine-tuning operations should listen carefully to the advice of this processing plant in Southern California—more consultation with customer feedback. Regardless of the size of the company’s companies or the professions they are engaged in, they should seek advice from them in order to find the right solution and to better improve the current work, which is also indispensable for any workshop processing strategy. An important part.
Figure 1 A tank part is being machined on a rotating table of a Femco BMC-110R2 machine.
It can be seen from the figure that the machine tool is drilling the welding part on the tank
As recently discovered at this Torrance processing plant in California, customer feedback may be staggering, often reaching unexpected potential effects.
A recent survey showed that Ace Clearwater Enterprises has adopted a new MRP system on a boring and milling machine it owns, thereby improving the company's process level in the processing plant, which not only speeds up the production cycle of the processing plant. At the same time, it also provides customers with better services. These customers include Honeywell, General Electric, Boeing, Lockheed Martin, Textron, Cessna, and Pratt Whitney.
Ace Corporation is located in Southern California and has 3 factories within 10 miles2 (1 mile2 = 2.59 × 106m2) and employs 200 people. In only one of the processing plants, the company has eight vertical milling machines, one horizontal machining center, one CNC double column machining center, six CNC lathes, and two water jet cutting machines. The company has been providing processing services for the aerospace industry and the power industry since 1949. In the early days of its establishment, the company mainly contracted welding projects from airlines. After gaining a good reputation in welding engineering, the company began to gradually expand its business scope, including various engineering fields, metal forming processes, elbows, machining, waterjet cutting, and titanium, Inconel, aluminum and stainless steel structures. The assembly of materials and other services.
Mr. Johnson, vice president of the company, conducted in-depth and meticulous research and made every effort to improve service quality in order to better meet customer requirements. The results of the survey show that although the customers are basically satisfied with the quality of the products, they are not satisfied with the actual delivery date of the products. In order to solve this problem, Ace has developed a set of plans whose core task is to shorten the delivery time of the processing plant products while at the same time increasing the production capacity as much as possible.
Mr. Johnson explained: “Logically speaking, our next step is to clarify the problem and then work out the best solution. We need to understand where the workpiece has reached the processing process and where the key bottlenecks occur. ."
In the past 12 years, Mr. King Lum has been the director of the workshop responsible for the progress of the company. With his help, the company decided to adopt a new MRP system to enhance the visibility of all expenses and do everything possible to increase the processing plant. The level of craftsmanship.
Figure 2 The extended spindle is drilling in the welded part of the tank
Mr. Johnson further explained: “We will go through everything: from procurement, the compilation of bar codes ... including everything you name. All of this makes us consider adopting a system called Symix, which includes everything, including Time cards, purchases, receipts, valuations, and accounting."
Once King Lum's digital environment system is fully operational, anyone can get an intuitive print and transfer drawings at the terminal. This system operates to understand up to 40 000 parts that are being produced in the workshop. However, Ace has not yet enabled this system.
The company's second step is to check all the equipment in the workshop and whether it has the opportunity to fine-tune their production sequence. Since then, Ace has discovered that none of the equipment is capable of machining large weldments. The horizontal machining center in the workshop is too small, and the workpiece needs to be clamped on different fixtures to complete the entire process. Several vertical machining centers in the workshop also require multiple clamping methods when machining parts.
Mr. Johnson said: "We processed some molds, some of the weight can reach 15lb (1lb = 45536kg), 18lb, 20 000lb, the largest processed mold even reached 44 000lb."
Since the company's machine tools are not suitable for processing heavy molds, Ace had to transfer many of its CNC machining operations to outsourced factories. With the continuous increase of business, this arrangement seems to make the already very sensitive delivery problem even worse.
Based on this, the company decided to purchase some large-scale equipment, which is the best way to solve large-scale workpieces in the company's workshop. So the company purchased four new large-scale machine tools, one of which was a Femco BMC-110 R2 boring and milling machine. This special machine includes 4-axis linkage control and Fanuc 18MC control system. The body of the boring and milling machine adopts a cast iron structure, and the box rails are quenched and ground by heat treatment. The Y-axis headstock travel of the R2-type machine tool has doubled, the X-axis travel on the table has increased by 50%, and its longitudinal Z-axis travel has also greatly increased compared to the company's previous machine tool travel. The X, Y, and Z axis travels are: 78.74 in. across the table (1 in = 25.4 mm), 70.87 in. of headstock travel, and 66.93 in.
Now, the size and space of this machine are sufficient to handle the various workpieces produced in today's workshops. After using the extended spindle and rotating table, the machine can be used to complete various processing tasks for large workpieces at a time. Now, the workpiece can be chucked in a universal fixture, so there is no need to use a compromise of multiple different compound angles to approach the workpiece during processing.
Mr. Dick Larry, Production Engineering Manager, said: “This expanded production capacity allows us to further improve our work efficiency. The workpiece does not need to be moved at all, and therefore requires little manual intervention, but the quality of processing is unambiguous. All this makes us The production cycle is reduced by 50%. It took us 4 hours to process such a part before, but now it takes only 2 hours or less.â€
This boring and milling machine can also prepare mold bases for Ace's other machine tools that manufacture welded part forging dies. The company claims that this machine also has many other features that can help support the entire production process. The BMC-110 R2 is generally used for milling and drilling large workpieces that are difficult to machine on other machines. The machine was also used to repair other older equipment. As Mr Larry said, the company sees this new type of milling machine as a tool and an asset for the workshop to accept the outsourcing processing business.
Mr. Larry said: “Recently, we are processing a batch of stainless steel storage tanks and preparing customers for Brazil. The boring and milling machines reduce the time for workpiece debugging and mounting by 75% when machining these parts, and they no longer need to be Outsourced factory processing."
In the end he summed up: "Now, all the work is done in the factory, and according to our own engineering design and production, the destiny is completely in our own hands so that we can effectively apply our own machine tools and shorten the product delivery. Delivery period reduces overall costs."
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